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Old 05-22-2014, 05:30 PM   #1
Eastwood
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Join Date: Feb 2012
Location: Colorado
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1995 Impreza

Default Help with a water pump bolt that the EASY OUT sheared off in the bolt.

Hello Nasioc,

I have a water pump bolt on my 98 legacy outback that sheared off when i torqued it down. I tried the reverse out from irwin, that just stripped the bolt.

Then I tried using an easy out. Spent about 15 minutes drilling the bolt, then used the easy out. It broke off at least 3/8" into the bolt.

Since. I tried using a cobalt bit (the hardest they have at Lowes) with no luck, then i bought a welder to try the old "weld a nut to it" trick, which i have done before... not working. Sheared off 4 nuts and I'm not trying to ruin my block surface.

The bolt that is broken is the bolt at the 2-3 o'clock position. My question is Nasioc: can i simply not use this bolt and avoid having leaks?

I have a new pump, gaskset, and water pump silicone.

Will i be okay with 5 bolts instead of the 6 or is this bolt a must?

Thanks

Eastwood.
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Old 05-22-2014, 06:30 PM   #2
DampedSubaru
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The 6th bolt is a must. The pump needs to seat uniformly against the block for proper sealing.
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Old 05-22-2014, 08:47 PM   #3
Eastwood
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So I was reading on a machinist blog about what to do when you encounter my issue. The best advice was to drill relief hole into the surrounding area (my block) to allow the swollen bolt to be remove with a hammer and chisel and breaking it out.

This may seem stupid to do, but there is absolutely no way i could get that bolt and easy out removed in my current situation. I drilled out the debris, and sealed everything up with a nice amount of silicon and used the OEM metal gasket.

This was the worst repair experience of my life........ IF my engine isn't going to hold water anymore, then ill simply have to replace the block.

Ill let you guys know what happens.... If my car will hold water with 5 bolts instead of 6. wish me luck!

peace
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Old 05-23-2014, 11:44 PM   #4
DampedSubaru
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I don't suggest starting the car with only 5 bolts installed. But it is your car.. Lol. Hopefully you'll be okay. But I highly suggest you get the problem fixed. Have you tried heating up the bolt and hammering it? And cooling it off? Sometimes that can do the trick.
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Old 05-23-2014, 11:49 PM   #5
OilyPablo
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There remains a solution.

Mototool (Dremel) and diamond bits. You will need maybe 3-5 bits. I like the little ball head style. Chuck one up and just grind the stud only and the hunk of broken easy out. Go slow and just be super careful. Then retap the hole and insert a new stud.
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Old 05-23-2014, 11:54 PM   #6
OilyPablo
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Quote:
Originally Posted by Eastwood View Post

Then I tried using an easy out. Spent about 15 minutes drilling the bolt, then used the easy out. It broke off at least 3/8" into the bolt.
Never, ever trust easy outs again. They will burn you every time. The aggravating thing......you were so close! Instead of drilling to insert an Easy Out, use a left handed drill bit and drill on R. As you drill and work the bit, with any luck it grabs the stud and out it comes.
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