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Allis Chalmers Discussion Forum

WD water manifold broken bolt

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Greg (TX)

08-27-2003 16:26:51

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Hi All,
I have a bolt broken off in the water manifold of a WD, it is the early engine series with the water manifold that looks like an elongated U or refrigerator handle (part # 210156). The broken bolt is one of three that secures the thermostat housing to the water manifold. The bolt is broken off below flush, I tried to get it out with an easy-out only to break it off inside the bolt. And the easy-out is broken off flush with the top of the broken bolt shaft. I took it to a local machine shop only to be told they couldn't grind it out because of the easy-out hardness. Isn't there a way to grind it out? How about melting it out? I was told the bolt is too small (7/16") to be melted out without damaging the manifold. If it is hopeless does anyone have a reference where such a part might be had?
Thank you for any help you can provide.

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Scott A, MO

09-01-2003 08:26:47

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 Re: WD water manifold broken bolt in reply to Greg (TX), 08-27-2003 16:26:51  
If you get this far as Dave described and the threads are damaged to the point that they don't work, I highly recommend buying a heli-coil kit to install the same threads back into the originals. I have used these kits (available at all parts stores like NAPA,) and love them. I have found, that buy starting off with the broken bolt ground flush to the housing, then center punched and drilled out for the heli-coil tap first, is more successful. It provides for greater stability for the drill bit to drill straight other than slowly opening the hole, possible causing it to be oblong and none-centered. making your heli-coil tap cut less material and your coil to hold less material. good luck, let me know how you did.

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Greg (TX)

09-22-2003 15:04:04

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 Re: Re: WD water manifold broken bolt in reply to Scott A, MO, 09-01-2003 08:26:47  
I was able to find a machine shop that ground it out and put a heli-coil in. Works great. Thanks to everyone for their help and advice, I now know a couple of more options to try should (when) this happens again. It was a harsh lesson but I've learned to never try an easy-out again.

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Dave K

08-31-2003 13:16:45

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 Re: WD water manifold broken bolt in reply to Greg (TX), 08-27-2003 16:26:51  
I broke one of mine also but (fortunatly) did not try to use an easy out. Never have had any luck with them except to break off! Anyway Here is how I got mine out. I carefully center punched the broken bolt, you want to be as certain as possible to be on center of the broken bolt, Then run a drill bit in which is slightly smaller than the threaded bolt hole, (you can try a bit for size in one of the bolt holes that are open.) After drilling so there is just a thin skin of the bolt left you can use a dental pick or small chisel to pull what is left of the bolt away from the threads. Once you get this out run a thread chaser in the tapped hole. If this does not work you may have to drill and retap the hole to a larger size.


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Dick L

08-27-2003 18:00:30

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 Re: WD water manifold broken bolt in reply to Greg (TX), 08-27-2003 16:26:51  
I have taken out easyouts with a small grinding stone in Dremal drill. Takes a spell but does not cost what a machine shop would charge. Some machine shops have a type of EDM machine that is designed for taking out hard bolts, broken carbide drills, as well as easyouts. It uses a small brass or copper tube that has oil pumped thru the center as it burns or blasts the object out. If you can not find a machine shop that has one of these you should have one around that has an EDM machine. Any large mold shop would have one.

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