Water pump 3 broken bolts

[ZionXIX]

If you buy the "OE" Aisin pump from FCP, it does not come with bolts.

[jsrnsis]

An update to this.
100mm is the magic number for clearance of the bottom bolts.
I tried for about 6 hours welding nuts onto the end of the studs with no success. I tried different nuts, washers, small racks built up, just gunning it, pre heating the area. A few attempts took enough force that it exceeded the initial force that broke the bolt in the first place. I practiced before hand by welding the same type of nut to the threaded end of an old water pump bolt, this nut got red hot, and the joint was so good that when I finally got it to break, it ended up just breaking the bolt, not shearing off the weld. I believe the block is too big of a heat sink to get a good enough joint, but I'm just a guy with a harbor freight welder so thats speculation.
I also tried to use a "rocketsocket" on built up weld bead, but the shape was too irregular, it would strip the outside layer off but the material that was left was too hard for the flutes to dig in.
After these attempts, we decided to drill it out. After spending a good amount of time marking out the center and using a tiny tiny Dremel ball end bit to make a divot (center punch won't fit in) we found out just how hard weld bead is. Drill bits made almost no progress, with no further hole after a couple of turns. Even tried Milwaukee cobalt bits. Tried the same bits in the same water pump bolt I practiced welding on and they dug in like it was hot butter.

I'm waiting on a right angle Dremel attachment to come in the mail, because these diamond burrs seem to have no trouble getting through. After seeing how hard the weld bead is, I might also try building a bead on the end of the studs again and cutting a slot for a flathead, and using a 3/8 drive screwdriver socket.

And something else I found out after removing the plastic timing belt back cover is that the bolt holes on the bottom left portion are through-holes, so if I end up mangling the threads I can put a longer bolt through and secure with a nut in the back. Not sure why they left the back open to corrosion though, I'm thinking that's why these are seized in so tight.

[volvolugnut]

Did you try impact on the broken bolts? Just a few sharp hammer blows on the end may loosen the bolt some. Also if you get a slot in the end of the bolt, try an impact screw driver like this:
https://www.homedepot.com/p/TEKTON-3-8- ... /205674679
These impact screw drivers really can work on stuck screws. You can also make a adapter for small sockets.
volvolugnut

[jsrnsis]

Did you try impact on the broken bolts? Just a few sharp hammer blows on the end may loosen the bolt some. Also if you get a slot in the end of the bolt, try an impact screw driver like this:
https://www.homedepot.com/p/TEKTON-3-8- ... /205674679
These impact screw drivers really can work on stuck screws. You can also make a adapter for small sockets.
volvolugnut

No room to swing a hammer, I don't know if that would even fit in the area between the frame and engine. Didn't impact on the bolts taking out, not sure if I used one of those low profile impacts if it would have freed the bolt or just ended up snapping it as well.

[volvolugnut]

You are really between a rock and a hard spot.
volvolugnutr

[abscate]

I hate to even mention it but my Engine picker is on Long Island and we could get it up to you if needed.

[Sveedy]

^ That's where I'm thinking this is headed....
Might as well make the most of it, and start thinking of other things that can be done while it's out.

[454cid]

I also tried to use a "rocketsocket" on built up weld bead, but the shape was too irregular, it would strip the outside layer off but the material that was left was too hard for the flutes to dig in.

I have a set of import copies of the Rocketsockets, and they do work. I found that I needed to hammer/tap the socket in place, first. I was disassembling the very rusted battery tray from the inner fender on a 69 Buick Electra.

You have a situation on your hands that I would be very distraught over.... broken bolts AND no room to work.

[jsrnsis]

I also tried to use a "rocketsocket" on built up weld bead, but the shape was too irregular, it would strip the outside layer off but the material that was left was too hard for the flutes to dig in.

I have a set of import copies of the Rocketsockets, and they do work. I found that I needed to hammer/tap the socket in place, first. I was disassembling the very rusted battery tray from the inner fender on a 69 Buick Electra.

You have a situation on your hands that I would be very distraught over.... broken bolts AND no room to work.

Using the side of a carpenters hammer and many small taps let me get the rocket socket on part of the stud sticking out that it just machined down, there wasn't very much to grab on. They work really well where there's an actual stripped head to grab on to, those little brake rotor retention screw/pins get pretty soft and prone to rounding off.

^ That's where I'm thinking this is headed....
Might as well make the most of it, and start thinking of other things that can be done while it's out.

Well having the engine out would make getting the timing and serpentine belts back on a lot easier at least. It's hard to think what else would need to be changed other than anything I break getting the engine ready for removal.

I hate to even mention it but my Engine picker is on Long Island and we could get it up to you if needed.

If it comes down to it I might have to take you up on the offer. The guides for engine removal out of the top look pretty straightforward, but once a job gets started it seems nothing is simple.

You are really between a rock and a hard spot.
volvolugnutr

I just keep telling myself that if the timing belt ended up snapping or the pump went out in 10,000 miles I'd be in a much harder spot. I think I have a semi-permanent residence between a rock and a hard spot by now.

[volvolugnut]

I am guessing the 850 does not have removable/foldable soft inner fenders like the P2 models. With the P2, you can get some access from the outside with the wheel off.
volvolugnut