Dodge

Dodge Repair Questions? Ask a Mechanic for Answers ASAP

Ask an Expert,
Get an Answer ASAP!

I have a 2001 dodge durango 4.7. while taking out the thermostat…

Customer Question
I have a 2001 dodge...
I have a 2001 dodge durango 4.7. while taking out the thermostat the bolt that holds it in broke off. we have tried to get it out but are having no luck. any suggestions?
Submitted: 8 years ago.Category: Dodge
Show More
Show Less
Ask Your Own Dodge Question
Answered in 1 hour by:
6/25/2010
Dodge Mechanic: Thomas, Dodge Mechanic replied 8 years ago
Thomas
Thomas, Dodge Mechanic
Category: Dodge
Satisfied Customers: 1,543
Experience: Mechanic with 15 years exp.
Verified

Hello have you tried drilling a hole in the center of the bolt and using easy-out tool.

For removal of stubborn broken bolts is to drill them out, using a left hand drill bit and a reversible drill. (The good quality, variable speed, 3/8" models, which produce good torque at low RPM, work best.) As always with drilling holes, drill a small "pilot hole" first, then drill a larger hole through the broken fastener. (It's easier to drill centered and straight by using a small drill first, but be careful not to break the small drill!) Most bolts come out before the hole drilling operation is finished. (Then there is no need for "easy-outs," which sometimes break off in the drilled hole and make matters worse.)

We just happened to have a few tightly rusted studs and nuts, which all broke off when attempting to remove the nuts. The project was rear fender mounting studs in a 1930 Model A FORD. These studs are threaded into fixtures at the body, behind the rear wheel, where seventy years of road grime splashed on them. And back in those years nuts and bolts were not plated with zinc or other anti-rust coatings, as our modern fasteners often are. The nuts were nearly welded to the studs by rust, and the studs were equally rusted into threads at the body. It was impossible to remove the fenders without breaking the studs. This was about the worst possible case of corroded and rusty fasteners.

In photos, we will show the removal of the old studs, and also the tools we used for this work.

The first step is to flatten the surface at the end of the broken bolt. Where bolts have broken, the surface is often jagged and sloped, which will cause the drill bit to wander off-center, when attempting to drill the hole. The stud in the photo was broken just above the surface, and we used a grinder to flatten the surface at the broken stud. When a bolt is broken off below the surface of a threaded hole, a jagged break often can be flattened with punches to get a better surface for drilling.

We used a heavy hammer and center punch to leave a "dent" for the drill to follow. Without center punching first, it would be impossible to keep the drill in the center of the bolt.

Before this step, we drilled a small pilot hole using a 1/8th inch drill. (The small diameter drill is easier to keep straight and centered than a large diameter drill.) Then we used a ¼ inch drill to finish with this 5/16inch stud.

The drill will attempt to grab the bolt just when breaking through the backside. Typically, that's the moment when the broken fastener will spin out of the threaded hole. Also, when drilling through the broken bolt, vibration will help to break it free. And drilling completely through leaves the bolt as a hollow tube, which may allow it to slightly collapse and loose some its grip at the threads.

This classic case of rust frozen fastener, shown above, came out squealing and with much powdered rust pouring from the threads. Notice that the threads at the fastener are even galled. Before installing a new stud we oiled the threaded hole and cleaned the threads with a tap.

Notice that these are LEFT-HAND drills, and they must be used with a reversible drill. Ours are by Snap-On tools, and Snap-On offers more than one model of Left Hand drills. Snap-On tools are typically excellent in quality, but other tool companies also make left-hand drills. (Check with the tool dept. at Sears, or your favorite tool store.)

The drills in the set shown above are short length High Speed Drills, and are rated for drilling in steel and other metals.

The set shown below are COBALT, long length, left-hand drills. The Cobalt is harder material than the standard high-speed drills, and the Cobalt drills are our choice for drilling out grade 8 bolts.

 

The short-length drills, used with an angle-head drill motor, can get into places where lack of clearance would prevent working with a long drill and typical drill motor.

Sometimes the longer drill bit with typical drill motor is needed to reach down into places where the angle-head and short drills would not work.

What ever the set-up used, the DRILL MOTOR should be powerful enough to drill at low RPM without stalling. Smooth running, powerful, and strong even at low RPM drill motors are best suited for this work.

IMPORTANT

As with any drilling operation, watch for chips while drilling. When making chips material is obviously being removed. If the drill is smoking and not making chips, then stop immediately. The drill may have to be sharpened, and probably reduce the RPM while drilling.

If a fastener does not come out with this left hand drill method, there are various types of "easy-out" extractors. Or, sometimes there is opportunity to drill an over size hole and then re-thread the hole to the next size larger. Some applications can use the next size larger bolt, otherwise the "heli-coil" method can restore the threaded hole to its original size. But, these alternative methods will require drilling first, so the left-hand drill method is never a wasted effort.

Two types of "EASY-OUT" extractors are shown in the photo above. When available, the type on the right is a favorite and has been less likely to break off in the broken bolt. But the three at the left have also been successfully used to remove broken bolts.

Especially in soft aluminum, the "HeliCoil" thread repair kit is very useful. The hardened steel thread insert actually adds strength when used in soft metals such as aluminum. The method is to drill the proper size hole for the next size larger thread tap. Then cut new threads in the drilled hole using the tap. And then use the tool to install the new thread insert. The thread insert is threaded both inside and out.

And always when using a thread tap, turn it in about 1/3 turn at a time, or until it begins to feel snug. Then back it up to cut the removed material. And then turn the tap in some more. (Simply forcing the tap into the hole will plug the tap and not result with good threads.)

TIP

A stud is stronger than a bolt, especially when the threads are questionable, which sometimes is the case after struggling to remove a broken bolt from a threaded hole. Minor damage to threads when struggling to remove the broken bolt can reduce the strength of the threads. And then when the new bolt is tightened into place, sometimes the remaining threads will pull out.

With correct stud installation, the stud is screwed into the threaded hole without applying pressure to the threads, and without galling the threads. After stud installation, the part is slipped over the stud, then install the correct washer, and then tighten the nut.

The stud is stronger because thread contact at the stud and at the threaded hole will be stationary at the time pressure is applied (when tightening the fastener). But when a bolt is used to mount a part, the bolt is rotated in the threaded hole during tightening, which can tear out weak threads.

When installing the stud into the threaded hole, the author prefers to strengthen and anchor the stud into place with Loctite. (Rather than double nut the stud and force it against the bottom of the drilled and threaded hole.) The "red version of Loctite," is preferred. ("stud and bearing mount" purpose version, it's the permanent version)

No doubt there will be times when clearance problems will make it impossible to use a stud, rather than a bolt. Sometimes there is not room to slip a large part over a stud, but rather the part has to be slipped into place from the side. (The stud gets in the way-making it impossible to slip the part into place from the side.) But when a stud can be used rather than a bolt, the stud will result with greater fastener strength than the bolt.

 

Ask Your Own Dodge Question
Was this answer helpful?

How JustAnswer works

step-image
Describe your issueThe assistant will guide you
step-image
Chat 1:1 with a dodge mechanicLicensed Experts are available 24/7
step-image
100% satisfaction guaranteeGet all the answers you need
Ask Thomas Your Own Question
Thomas
Thomas
Thomas, Dodge Mechanic
Category: Dodge
Satisfied Customers: 1,543
1,543 Satisfied Customers
Experience: Mechanic with 15 years exp.

Thomas is online now

A new question is answered every 9 seconds

How JustAnswer works:

  • Ask an ExpertExperts are full of valuable knowledge and are ready to help with any question. Credentials confirmed by a Fortune 500 verification firm.
  • Get a Professional AnswerVia email, text message, or notification as you wait on our site. Ask follow up questions if you need to.
  • 100% Satisfaction GuaranteeRate the answer you receive.

JustAnswer in the News:

Ask-a-doc Web sites: If you've got a quick question, you can try to get an answer from sites that say they have various specialists on hand to give quick answers... Justanswer.com.
JustAnswer.com...has seen a spike since October in legal questions from readers about layoffs, unemployment and severance.
Web sites like justanswer.com/legal
...leave nothing to chance.
Traffic on JustAnswer rose 14 percent...and had nearly 400,000 page views in 30 days...inquiries related to stress, high blood pressure, drinking and heart pain jumped 33 percent.
Tory Johnson, GMA Workplace Contributor, discusses work-from-home jobs, such as JustAnswer in which verified Experts answer people’s questions.
I will tell you that...the things you have to go through to be an Expert are quite rigorous.

What Customers are Saying:

I AM VERY GLAD THAT I TOOK A CHANCE ON YOUR PROBLEM SOLVING SKILLS. I WAS SUCCESSFUL IN REPLACING THE FUEL PUMP. MY TRUCK RUNS LIKE A CLOCK. IT RUNS LIKE THE DAY I BOUGHT IT. NO LUNGING FORWARD, THE TURBO REACTS THE SECOND I STOMP ON THE GAS, AND IT HAS A LOT MORE POWER AND EVEN SOUNDS BETTER TO ME. IT SAVED ABOUT $500.00 BY DOING THE WORK MYSELF. I GIVE YOU ALL THE CREDIT FOR YOUR DIAGNOSING THE PROBLEM, JUST FROM THE SYMPTONS I GAVE YOU OVER THE e MAIL. I WILL USE YOUR WEB SITE AGAIN AND REFER MY FRIENDS. THANKS SO MUCH FOR THE HELP.

TOM WHITTAKERUSA

Just a quick line to tell you how pleased I am to have my brakes working properly after all this time. Your answer was what I needed. I would certainly recommend you highly. God bless!

Rev. Jerry BaysingerHolts Summit, Mo

I recently asked a question about my 2005 dodge ram, and I just wanted to let my Expert know that he hit the nail squarely on the head with his answer. I wanted to thank him again.

GregPittsburgh, PA

Just a quick line to tell you how pleased I am to have my brakes working properly after all this time. Your answer was what I needed. I would certainly recommend you highly. God bless!

JerryHolts Summit, MO

I was skeptical at first but thought I'd give it a try. I was pleasantly surprised. Your site actually is a quality service that I would recommend to others in a heartbeat.

StanSayre, PA

Wonderful service, prompt, efficient, and accurate. Couldn't have asked for more. I cannot thank you enough for your help.

Mary C.Freshfield, Liverpool, UK

This expert is wonderful. They truly know what they are talking about, and they actually care about you. They really helped put my nerves at ease. Thank you so much!!!!

AlexLos Angeles, CA

< Previous | Next >

Meet the Experts:

Jerry

Jerry

Master Mechanic

1,754 satisfied customers

ASE Master tech, 30 years exp. troubleshooter, driveability tech

Chris

Chris

Shop Foreman

7,095 satisfied customers

Dodge/Cummins and Chrysler Certified Master Tech

Mopar Certified

Mopar Certified

Dodge Technician

6,073 satisfied customers

24 Year Chrysler/Dodge Certified Specialist

moparfl

moparfl

ASE Certified Technician

3,292 satisfied customers

ASE Master Tech Gold level Chrysler Status 30 years dealership exp

Dodgerench

Dodgerench

ASE Certified Technician

2,822 satisfied customers

30+ years Dodge/Chrysler exp., ASE Master with L1 certification. Driveability/ combustion specialist

Tim Mohr

Tim Mohr

ASE MASTER TECH

2,363 satisfied customers

30 YRS EXPERIENCE, FOREIGN AND DOMESTIC, GAS AND DEISEL

Don - Mo Lurch

Don - Mo Lurch

Aftermarket & Factory Electronics

1,593 satisfied customers

Cert. Dodge & Chrysler Warnty, Heavy Line Mech, Mobile Electronics. Sales, Installation & Repair for 30 years

< Previous | Next >

Related Dodge Questions
Eimmission hose were does pcv line connact in back of motor,
eimmission hose were does pcv line connact in back of motor, someone else installed motor it had overdrive but did not hook it back up now I have small hose on brake boster with vaccum but don't know … read more
kalamykid
kalamykid
Pactor automotive
Vocational, Technical or Trade Scho
97 satisfied customers
You a robot or a person? Ok, I have 2001 Dodge Durango, I
I have 2001 Dodge Durango, I have know idea how to replace my belt tensionor … read more
Tim Mohr
Tim Mohr
ASE MASTER TECH
Master's Degree
2,363 satisfied customers
I have a 2005 dodge Durango 4x4 4.7 engine. I am trying to
I have a 2005 dodge Durango 4x4 4.7 engine. I am trying to figure out what the allen plug next to oil sensor switch and above oil filter is for? … read more
sprinkles08
sprinkles08
Technician
High School or GED
11 satisfied customers
Durango: 2001 Dodge Durango 4.7 Vin: 1B4HS28N41F572547 Wipers
2001 Dodge Durango 4.7 Vin: 1B4HS28N41F572547 Wipers not working...all fuses are good, tried a new motor and that didnt work...is there a module that the wipers work off of? Suggestions?… read more
Jerry
Jerry
Master Mechanic
Vocational, Technical or Trade Scho
1,754 satisfied customers
I have a 2001 Dodge Durango 4.7 200k Starts and runs but no
I have a 2001 Dodge Durango 4.7 200k Starts and runs but no spark on 1234 coil,changed ecm and coils and crank positioning sensor along with cam sensor and still no luck?… read more
Tim Mohr
Tim Mohr
ASE MASTER TECH
Master's Degree
2,363 satisfied customers
listen you are more concerned with a rating than giving a proper
listen you are more concerned with a rating than giving a proper answer for example how many reputable salvage yards are out there they are going to tell you it will work just to make sale so by comin… read more
Tim Mohr
Tim Mohr
ASE MASTER TECH
Master's Degree
2,363 satisfied customers
i have a 2002 dodge ram 1500 with 4.7 motor that has the 16
i have a 2002 dodge ram 1500 with 4.7 motor that has the 16 tone cam . i need to replace the motor and wondering if the motor with 4.7 and 16 tone cam from 2001 and 2002 dodge dakota and durango will … read more
Kavey
Kavey
86 satisfied customers
Dakota: I began to replace the thermostat on my dodge 4.7 liter.
I began to replace the thermostat on my dodge 4.7 liter. When removing the lower of the two bolts which hold the thermostat housing the lower bolt broke in half. What the heck do you do?? Any ideas? t… read more
Chris (aka - Moose)
Chris (aka - Moose)
Vocational, Technical or Trade Scho
108 satisfied customers
2001 dodge Durango: stalled..gauges wont work and odometer..pcm short
I have a 2001 dodge Durango with 4.7 and it just stalled. All gauges won't work and odometer says "no bus" any ideas so I can get off the aide of the road? PCM short?… read more
Auto Go
Auto Go
Shop Owner
Associate Degree
590 satisfied customers
2004 dodge durango slt: truck cools down on hwy driving...flushed
2004 dodge durango slt 4.7 overheats during stop and go driving and ideling. truck cools down on hwy driving. Has recently been flushed, but problem persists. Any suggestions. Thanks… read more
jim
jim
Vocational, Technical or Trade Scho
702 satisfied customers
2001 Dodge durango: Idle speed..fast 1300 rpm..ac..check engine light
Idle speed is fast 1300 rpm, with ac running, about 900 without, 2001 Dodge durango It is not throwing any codes no check engine light do I need to change sensor?… read more
Mopar Certified
Mopar Certified
Dodge Technician
Vocational, Technical or Trade Scho
6,073 satisfied customers
2000 dodge durango: V8..speedometer and gages dont work..problem....
Hello...We have a 2000 dodge durango 4.7 V8. We put in a 4.7 engine and transmission with all the wiring into a 5.2 body durango and we now have a problem with all the wiring the speedometer and gages… read more
David Dill
David Dill
Master Level Chrysler Technician
High School or GED
834 satisfied customers
2002 Ram 1500: Was trying to replace my thermostat when one..bolts
I have a 2002 Ram 1500. Was trying to replace my thermostat when one of the housing bolts broke off. I bored it out, and when I tried to tap it again, the tap broke. I'm really frustrated, and I'm won… read more
ASEMaster35yrs
ASEMaster35yrs
Vocational, Technical or Trade Scho
1,314 satisfied customers
I have an intermittent anti-freeze leak dripping..radiator..water pump
I have an intermittent anti-freeze leak dripping off the plastic shield below the radiator and pulleys. I don't think its the water pump. Can you recommend any common causes to check out?… read more
Mopar Certified
Mopar Certified
Dodge Technician
Vocational, Technical or Trade Scho
6,073 satisfied customers
1999 Dodge Durango: the serpentine belt broke..ve replaced..tension
I have a 1999 Dodge Durango, the idler pulley broke and the serpentine belt broke. I've replaced the idler pulley and I'm try to replace the serpentine belt. How do you lower the tension belt pulley t… read more
sprinkles08
sprinkles08
Technician
High School or GED
11 satisfied customers
2001 Dodge durango. Is it possible/feasable to put in a 5.9 motor.
i have a 2001 Dodge durango. Is it possible/feasable to put in a 5.9 motor. My 4.7 is shot, rebuilds are very expensive and based on the number of vehicles with failed 4.7 motors I see at auction even… read more
Leo
Leo
Associate Degree
572 satisfied customers
2005 dodge durango: s temp gauge very seldom moves
My 2005 dodge durango''s temp gauge very seldom moves. I have seen it move into the normal zone just a couple of times.… read more
a-mechanic
a-mechanic
Shop Foreman
Associate Degree
298 satisfied customers
Remove a fan clutch on a 2001 dodge durango with a 4.7 l engine?
how do you remove a fan clutch on a 2001 dodge durango with a 4.7 l engine?when i put a wrench on bolt to lossen it turns the whole pully and i cant get it off… read more
Leo
Leo
Associate Degree
572 satisfied customers
Disclaimer: Information in questions, answers, and other posts on this site ("Posts") comes from individual users, not JustAnswer; JustAnswer is not responsible for Posts. Posts are for general information, are not intended to substitute for informed professional advice (medical, legal, veterinary, financial, etc.), or to establish a professional-client relationship. The site and services are provided "as is" with no warranty or representations by JustAnswer regarding the qualifications of Experts. To see what credentials have been verified by a third-party service, please click on the "Verified" symbol in some Experts' profiles. JustAnswer is not intended or designed for EMERGENCY questions which should be directed immediately by telephone or in-person to qualified professionals.

Disclaimer: Information in questions, answers, and other posts on this site ("Posts") comes from individual users, not JustAnswer; JustAnswer is not responsible for Posts. Posts are for general information, are not intended to substitute for informed professional advice (medical, legal, veterinary, financial, etc.), or to establish a professional-client relationship. The site and services are provided "as is" with no warranty or representations by JustAnswer regarding the qualifications of Experts. To see what credentials have been verified by a third-party service, please click on the "Verified" symbol in some Experts' profiles. JustAnswer is not intended or designed for EMERGENCY questions which should be directed immediately by telephone or in-person to qualified professionals.

Show MoreShow Less

Ask Your Question

x