How do I remove a broken bolt from the thermstat housing piece and replace with a new bolt?
It's not a bolt but a stud which is like a bolt but doesn't have a bolt head and has threads on both sides. To remove it, you'll need a Stud Removal Tool. What it does is grabs onto the stud and with a attached rachet wrench, you can twist it off... or you can use a Vise Grips.
Here's the link to the Stud Removal Tool ... it's less than $10:amazon.com/16-Stud-Remover/dp/B001U6HIV.
If you're using an E-Z-type extractor, carefully drive the extractor in until it bites the bolt securely, then unscrew the bolt using an adjustable wrench or T-handle on the extractor. If you're using a screw-type extractor, screw the extractor into the bolt in a counterclockwise direction until it bites into the bolt and unscrews it. If you do not have an extractor set, then you must continue enlarging the hole, using progressively larger drill bits, until the threads can be disengaged from the hole.
Dig the threads out using the drill bit or a dental pick.
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