Water pump replace, broke 2 bolts! HELP! - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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Old 12-17-2007, 12:39 PM   #1 (permalink)
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Water pump replace, broke 2 bolts! HELP!

Put the new water pump on yesterday. Torque spec was 35-45 ft/lbs. I torqued all 9 bolts to 40 lbs. Test drove and one of the bottom bolts (driver side) was seeping. Rolled under the truck with the torque wrench set at 45 lbs and the bolt tightend some more. Never did hit the stop on the torque wrench with that bolt. Got up on top and started checking the other ones and broke 2 trying to retorque the bolts.

Now I am kind of in trouble because one of the two that broke is a long one (there are three lengths) and the broken off part is deep in the hole in the block. I havenít taken the pump back off yet so I donít know if the other one is proud of the machined face but the long bolt I am sure is deep in there.

Two questions:
1) What could have caused these bolts to break? The engine was hot after just test driving, could this be a factor?
2) Any suggestions as to how to deal with the broken off bolt deep in the long hole?

My last resort is to remove the broken one that should be right at the face, replace all bolts with new ones, and use RTV in the gasket area for the broken one and not have a bolt there.

Please help, I feel like someone just kicked me HARD!
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Old 12-17-2007, 12:45 PM   #2 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

<div class="ubbcode-block"><div class="ubbcode-header">Quote:</div><div class="ubbcode-body"> I am sure is deep in there.
</div></div>

I would think it won't be too deep.. seeing as how it most likely cant break after the threads start..

Take the pump back off & let us know what you find....
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Old 12-17-2007, 12:45 PM   #3 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: r2j2</div><div class="ubbcode-body">Put the new water pump on yesterday. Torque spec was 35-45 ft/lbs. I torqued all 9 bolts to 40 lbs. Test drove and one of the bottom bolts (driver side) was seeping. Rolled under the truck with the torque wrench set at 45 lbs and the bolt tightend some more. Never did hit the stop on the torque wrench with that bolt. Got up on top and started checking the other ones and broke 2 trying to retorque the bolts.

Now I am kind of in trouble because one of the two that broke is a long one (there are three lengths) and the broken off part is deep in the hole in the block. I havenít taken the pump back off yet so I donít know if the other one is proud of the machined face but the long bolt I am sure is deep in there.

Two questions:
1) What could have caused these bolts to break? The engine was hot after just test driving, could this be a factor?
2) Any suggestions as to how to deal with the broken off bolt deep in the long hole?

My last resort is to remove the broken one that should be right at the face, replace all bolts with new ones, and use RTV in the gasket area for the broken one and not have a bolt there.

Please help, I feel like someone just kicked me HARD!
</div></div>Where did you read the procedure to torque those bolts to 35-45 ftlbs. That is way to high. For a while the article on this site recommended that torque but after vocal criticism it was finally corrected to 15-22 ftlbs. Look here.
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Old 12-17-2007, 12:52 PM   #4 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

The torque spec came right out of the Ford service manual! Now I can't count on what I read in there? Great!

I still don't understand why these bolts would break at 45 ft/lbs. This is not really all that much torque.
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Old 12-17-2007, 12:58 PM   #5 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

Look at the size of the bolts.
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Old 12-17-2007, 01:08 PM   #6 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

You can probably get them out since you just put them in and they won't be "seized" in the hole.
A trick I use in my machine shop is to get a left handed drill bit,center punch the broken part before you start to drill.

When you start drilling the bit will grab(most of the time) and spin the broken part right out.
Now I know that it's gonna be tight quarters in there so be very careful! Use some PB or LiquidWrench too.
If you drill off-center, you're screwed!

Also again since they aren't seized, a regular drill bit and "easy-out" will most likely work too.

Again, take your time! I have guys call me all the time with bolts broken off in stuff.
The first question I ask is "have YOU tried to get it out yourself"? If they have it's usually difficult to fix their screw-up!
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Old 12-17-2007, 01:14 PM   #7 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

An Easy-Out would be a good start. An angled drill works best for drilling in the tight space. You'll get her out. Retorque 15-20 ftlbs.
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Old 12-17-2007, 01:17 PM   #8 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

Probably not the reply you are looking for but...
Were you using a clicker or a pointer torque wrench?
A pointer torque wrench would have displayed a flattening, and even a slight drop in torque before it broke.
This gives you time to abort and get the stretched fastener out.
I only use a clicker for non-critical torques like lug nuts, etc.
Take it slow from here.
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Old 12-19-2007, 03:53 AM   #9 (permalink)
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Re: Water pump replace, broke 2 bolts! HELP!

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: r2j2</div><div class="ubbcode-body">The torque spec came right out of the Ford service manual! Now I can't count on what I read in there? Great!

I still don't understand why these bolts would break at 45 ft/lbs. This is not really all that much torque. </div></div>That's not the only error in the '99 shop manual. [img]/forums/images/%%GRAEMLIN_URL%%/frown.gif[/img] Look at the bolt size to torque chart at the end of the engine specs to compare with what they tell you for the WP bolts. Someone screwed up on that publication.

It's been talked about a number of times here on TDS. You aren't the first one who's snapped WP bolts by following the erroneous torques in the Ford Manual. But I know that's not much consolation.

The tip on using a left hand twist drill bit is a good one. The stubs usually aren't tight in the holes. I've actually spun out broken bolts with a pin punch and hammer till I could grab them with pliers, but that won't help you with the one's that are in deep holes.
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