broken thermostat bolt

Discussion in 'Gen 3 Prius Main Forum' started by mhdriver, Jan 14, 2026 at 2:02 PM.

  1. mhdriver

    mhdriver Member

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    Well, pulling off the thermostat and when I got to the bolt, the head broke off. I did remove the thermostat and the bolt still protrudes. What is the best way to remove this?[​IMG] [​IMG]
     
    #1 mhdriver, Jan 14, 2026 at 2:02 PM
    Last edited: Jan 14, 2026 at 2:13 PM
  2. Dodge Propshaft

    Dodge Propshaft New Member

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    I'd carefully heat up the thermostat housing with a torch and use a vise grips to grab whats left of the bolt to remove it. If that doesn't work you can try to drill it out for using an extractor or drill it all out and helicoil.
     
  3. ASRDogman

    ASRDogman Senior Member

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    Please don't start a new thread for the same subject. Post it in the original postings....
    Heating it up to loosen it is the best way. Lot's of penetrating oil, and let it soak.
    You "might" be able to twist it out with vice grips.

    If not, you can drill a hole in the middle and hopefully and easy out will work.

    If not, drill it out and tap new threads.
     
    PriusCamper likes this.
  4. Mendel Leisk

    Mendel Leisk MMX GEN III

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  5. mhdriver

    mhdriver Member

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    Will post anything else in original thread. Got to say this is discouraging since it's not in the open. Getting penetrating oil and a torch today.
     
  6. ASRDogman

    ASRDogman Senior Member

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    Yes, it can be a pain. Try to stay calm, and be don't go fast.
    Do one thing at a time. It's tricky, but it can be done...
     
  7. mhdriver

    mhdriver Member

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    Where drilling it is difficult is that there's no way to get a drill down there that I can see. People say extractors rarely work if at all. I'm gong to heat it and then use penetrating oil to see if I can get it with vise grips.
     
  8. mhdriver

    mhdriver Member

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    Would you replace all the engine cooling hoses? 2015 with 205k miles. No apparent leak, but I seem to be losing a minute amount of coolant every 6 months.