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broken bolt in water pump housing

10K views 4 replies 4 participants last post by  cuda2000  
#1 ·
I am replacing the water pump on my 98 Grand Caravan with a 3.8. I was removing the last bolt, the top right one, and it got very tight. Obviously never seize was not used
it was going fine until the bolt broke.
I got an ez out and bit, but the bolt is about 5-6 inches up from where I can drill it horizontally. If I loosen the upper passenger side mount, the other pulleys on the back side of the engine won't let the engine drop far enough. Looking at the other 4 bolts, they almost make a square. I think that the o-ring and some rtv would seal enough to hold the water pressure.

Has anyone had this issue and tried my remedy with any success?
 
#2 ·
When this kind of thing happens, an angle drill has saved me many times.
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I have also drilled clearance holes though fenderwells to get a very long drill bit straight onto broken bolts.

You can try running it without this bolt, the most that will happen is you'll get to take it apart again and drill that bolt out.
 
#3 ·
I did the same as 1994 Sport. I bought a right angle DeWalt drill at Home Depot and some extra centerpoint bits. It was well worth the effort to me. When I drilled it, I was not quite perfect, so after I got it drilled, I tapped new threads and then drilled the new water pump to match before I installed it for good. It is still holding after many thousands of miles.

If you choose to NOT install that bolt, you are leaving essentially half of the face unsupported and I will almost guarantee you that it will leak.

That is the ONE bolt that has the back side of the threads open to all the road grime coming from the front.
 
#5 ·
Same thing happened to me a year ago. I bolted the new pump in with the remaining bolts, didn't use any RTV. Its been a year, no leaks. You are good to go.