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Discussion Starter · #1 ·
i have a 1992 ford bronco 5.0L 302 we were replacing the water pump when a water pump/timing cover bolt broke off :( not a prob we got it out the bolt had corroded to the inside of the timing cover and when we got the timing cover loose we were able to spin the whole thing and get the bolt out ya:) but :( we wanted to replace the thermostat so we tried to loosen the thermostat housing bolts and they broke off in the lower intake manifold what can i do we tried a backout to try to remove the bolts we actually broke the back out just the tip I was thinking maybe if the engine was hot it would make it easier to remove the bolts cause the metal would be expanded could this solve our problem? if so what do i need to do to heat up the engine can i run it without putting the timing cover back on? cause those timing cover gaskets are not cheap or should i use some kind of torch to heat up the lower intake manifold? thanks for the help we want the truck fixed any and all help is welcome i hope to get the truck fixed soon before it sits broke for another year
 

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aka: kemicalburns
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use a propane torch.

prior to removing any bolts were they sprayed down with liquid wrench or some type of penetrating oil?
 

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Discussion Starter · #4 ·
wow thanks for the quick response only stuff we would have used is pb blaster but i am not sure. how long would a propane torch take to heat up to a good heat to remove the bolts?
we tried to heat it up before with a propane torch but i guess we never heated it up for long enough
 

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PB Blaster is good stuff. I use a small plumber's torch and get the bolt red-hot. You ought to take out the distributor though and move as much wiring/hoses out of the way as possible. A few love taps with a punch and a hammer help as well to get things broken free. Worst case scenario, pulling the lower manifold isn't hard. If you end up doing that, run a thick bead of Black RTV instead of the little front and rear cork gaskets.
 

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Discussion Starter · #6 ·
I knew we would probably have to replace the lower intake i was just hoping that we might have a chance of getting the bolts out without removing it
now if we get the bolts out we need to re thread the holes right? and is it o k to replace the bolts with zinc plated grade 8 bolts? cause i hope that will keep the freaking bolts from breaking if we have to remove them again and can i get new bolts for the water pump and timing cover that are zinc plated and grade 8 from anywhere? thanks in advance fr any help.

:chili: pretty soon my bronco will be this brick wall ---->:banghead :chili:
:stupid
 

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Charlie don't surf..
'92 Ford Bronco XLT
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and another question should i use the cork gaskets on the timing cover or replace it with the Black RVT silicone?
No do not use cork gaskets, they'll leak. Get a good set up the fel pro rubber style ones with the steel core. They're more expensive but they won't leak on you.
 
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