Broke bolt off in head!

[FoxRod87]

I was just changing the thermostat and gasket cause it was leaking coolant. but broke one of the bolts off in the head. The left one broke. Was woundering if the front aluminum part on the intake comes off the manifold or is it one piece. Thanks.

 

[Orange...]

the front aluminum piece does come apart, I think there is 7-8 10mm bolts on the underside.

 

[DTNODYA]

Man I did the same thing a while ago. It was the left bolt also. It is good though, that the bolt that broke is the one on the left. The one on the right is REALLY in the head. The one on the left is sort of off to the side (so to speak). Here's a pic of mine, you can see the broken bolt if you look hard.

The bad part is that there was no way that bolt was coming out. I tried everything imaginable and it wasn't gonna happen. I had to drill it out (nerve racking) and re-thread it. I threaded it to a standard bolt because I had one that was the right legnth and Ford wanted a ridiculous amount of money for that bolt. 20 bucks or something crazy.

But honestly, to do it right, you are going to have to pull the intake off. Unless there is a lot sticking out the top. Mine broke almost flush.

 

[darkside03gt]

try a quality easy out from snap-on or craftsman. use a heat gun and heat it up well then use the easy out. dont heat it up too long because aluminum and steal heat up at different rates.

 

[FoxRod87]

I think I am going to go ahead and get a PI intake and put it on. Is it a good job or is it pretty easy to do and do I have to do any modifications to install a PI intake? Thanks.

 

[blackfang]

I think a good tap and die set will work like it has been mentioned.

 

[DTNODYA]

I went ahead and put a PI intake on mine when I changed it out. Well, not at first, I got a dorman replacement but then got a PI about a week later. The job isn't difficult, just takes time (the first time). I can tear that thing down stupid fast now!

I recommend taking the intake off, labeling/bagging parts, taking pictures as you go and then dealing with the broken bolt before doing anything.