Sears carries bolt extractor sets. Just carefully drill out the middle of the bolt with a carbide drill bit and make sure its the right size for the extractor you use, tap in the extractor and then turn the bolt out. Had to do this twice on my Jeep
i did the exact same thing i drilled it out pretty easily- make sure you tighten all the bolts to the proper torque specs b/c if you over tighten you'll get real nasty leaks- i also had that happen- once i tightened everything to factory specs it doesnt leak a drop
thanks for the tips, now i cant get the very last one out. i think its the longest one, its at about 4 o'clock. the thing wont budge. im afraid of breaking that one now. i tried heating but nothing. all this for a damn water pump.
Here’s the parts list for the broken water pump bolts. Not cheap, but it will get you fixed and back on the road…
A word about the links, if they don’t work, do a search on the part number (P/N). MSC updates their catalog regularly, and the pages may change, but the part numbers don’t. You will need the Adobe Acrobat viewer which is also a free download – http://www.adobe.com/products/acrobat/readstep2.html
http://www1.mscdirect.com/CGI/NNPDFF?PMPAGE=1096 Use drill bushing 5/16” OD, 5/32” ID, ¾” long, P/N 07010457, price $8.57 This centers the drill bit in the housing bolt hole so you don’t get off center and damage the water pump, timing cover housing or engine block
One step specialty item: See Drill-Out® Broken Bolt Extractors drill bushing, reverse twist drill & extractor all in one unit. Best to use when the bolt breaks off with the remaining part below the start of the threads. .P/N 05027164. Price $18.33 each. You MUST have a reversing drill motor (either air or electric) to use this bit.http://www1.mscdirect.com/CGI/NNPDFF?PMPAGE=19268
A long shank tap should be used to chase the leftover metal out of the original threads. Also recommended to clean the corrosion and dirt out of the threads before you reassemble everything. Cleaning the threads will help prevent the bolts from seizing next time (yes, there will be a next time).
See http://www.windsorfox.com for Stainless Steel Water Pump Bolts with Custom stainless steel studs. Allow the use of factory accessory brackets without hunting for obsolete parts or using spacers.
Kit comes complete with nine polished stainless 12 point bolts, four stainless studs and nine stainless oversized washers.
Price: $65.95
See http://totallystainless.net/totally.html for the bolts. Last time I checked, they didn't have the studs. Nice folks, very into cars of all types. They have all kinds of stainless fasteners for almost every car. The prices are very reasonable, less the $8 for the water pump kit without the studs.
The studs are a Motormite item available at your local Advance Discount auto Parts store.
Motormite Water Pump Stud Kits for Ford, Lincoln and Mercury cars and trucks w/3.8L, 4.6L, 5.0L, 5.8L.
Take a cardboard box, & turn it upside down. Count the number of bolts that hold the water pump on, don’t forget to count the 4 funny looking studs too. Poke a hole in the box for each bolt/stud. Arrange the holes in a circular formation, and mark the box at the 12:00 point. When you remove a water pump bolt, put it in one of the holes in the box according to where it came out of the water pump. When you are done, all bolts will be arranged it the exact same order and position that you removed them from the water pump. That makes re-installing them easy, no wondering where does this bolt go.
A long shank tap should be used to chase the dirt & corrosion out of the original threads before you reassemble everything. Cleaning the threads will help prevent the bolts from seizing next time (yes, there will be a next time).
Use lots of antiseize on the bolts to protect them from corrosion and make them easier to remove next time.
See the links in my previous post for new studs and/or stainless steel bolts.