guys,

while taking off my thermostat housing(to get the water temp sender out) the bolt broke off. Then trying to pry the housing off, it cracked in
half.

I have gotten both the bolt and housing off, thats not my problem....

My problem is that the damn temp sender is still stuck in there!! My dad and i have tried everything.....and the only left in the hole is the shell
of the sender...

Our only chance to get it out is to drill it out. Hopefully, with some luck, drilling it out wont ruin the thread, so i can still screw the cap
over it...

anyone got any other ways to get the bastard out? or got any advice for me when i drill it out?

thanks

-Jesse

Hey Jesse,

Have you tried to pry the sensor out from inside the thermostat hole? Have you used a lot of WD40? Try soaking the head in kerosene or diesel for a day, kerosene and
diesel are good penetrants.

Mareo

i havent taken the head off, so i cant soak it in anything....=(

the sender is fully butchered....nuthing but the brass (?) shell left, and it's stuck with super glue or
some shit...(not really)..

grrr.....pissing me off

Well being a plumber by trade I sometimes have to
do this with pipes and fittings but they are Mallable iron or steel. Brass is soft as is your alum head. I use a small fine toothed hack saw blade to cut the pipe from the inside enough
to
collapse in on it self. I can then either thread it out or curl it enough to pull it out.I usually have to split it with a screw driver,using it like a chizel to finish the cut so not
to damage the threads. We call the saw that uses this about 3mm
wide blade a tiny tim or small bow saw.I hold the blade with a rag as the frame is to big to get inside small pipes. It's slow but it works every time!
A rotory file might be better than a drill bit
if you try to mill it out.
Good luck!
Sageman

man straight up thats sad luck, so you pulled all the sensor and just the housing is left? im not sure how this area goes for heat, so probably dont heat it up... have you tried a screw
driver from inside? i thought that would have worked, ive got a spare housing if you need one, but you might be easier just to get one from a wrecker, those bolts to break is normal, get
some brand new ones the exact same thread and length, and you will be sweet for another 30 years. what about a straight soak with pure cooling flush or something, yeah i honestly dont know,
but of heat might do it, and it might not damage the head as there is no camshaft to damage. tried tapping the side to free it? soaked it with CRC? man best of luck, crazy.
choice from chris.

my dad got to it with the drill this monring, while i was asleep.....

now i have no thread, and half of the shell is stuck in there still....

Good news is i went to sprint auto parts, and got a new housing....bad news is it wasnt machined properly, and i had to take it off and on 5 times before it stopped leaking.
I ended up cramming half a tube of gasket goo silicone stuff onto the thing...

at least it works...

but as for the temp guage.....i'm fucked....

it's stil in there, and nows there's no thread.... But at least i can drive the car now...

tis going to be a tuff mission..... i'm going to hafta take over from you chris, since you dont have your datto anymore =( hard luck dude....

i just hope she's worth it, and doesnt dump you in 2 weeks....*touch wood* hehehe

cya's

try eazy outs you can get them at the hard wearstore