1998 Toyota Sienna Thermostat Housing Stud Broken

Tiny
KC0DXH
  • MEMBER
  • 1998 TOYOTA SIENNA
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 166,000 MILES
How can I fix a broken thermostat housing stud? As I was tightening the rear-most nut, the stud broke. There are no threads left, but the unthreaded portion of the stud is intact.

What options do I have? I'm not the most able of persons in this arena, so please make your answers specific. You won't offend me by answering like you're talking to a five year old.


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Tuesday, February 24th, 2009 AT 11:43 AM

5 Replies

Tiny
KHLOW2008
  • EXPERT
Hi kc0dxh,

Thank you for the donation.

Good thing you still have a long portion left of the stud but bad news is it is in a rather unaccesible location.
Check with your local parts outlets that has a loan program for a stud removing tools. With it clamped onto the stud, the stud can be removed and replacement made.

You can try removing the upper hose for accessibility and try removing the stud with the aid of a grip plier. Filing the stud on one side to make it slightly flat for better grip would help. Spraying some rust remover and letting it soak prior to removing would help.

Do NOT allow plier to slip and damage the stud as it would cause difficulty in removing. If the stud is damaged too bad, you would have to drill it out and retap the threads.

Worse case scenario is to remove the complete housing and clamp the broken stud on a bench vise to remove.

While working on it, take care not to damage the housing to prevent leaking.

To install new stud, use 2 nuts to lock onto each other on the stud and tighten, need not be too tight, 8 ft. Lb would do.
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Tuesday, February 24th, 2009 AT 12:17 PM
Tiny
KC0DXH
  • MEMBER
So, are you saying that stud will just unscrew, provided I can get a good grip on it?
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Tuesday, February 24th, 2009 AT 12:30 PM
Tiny
KHLOW2008
  • EXPERT
Yes, it is threaded on the other end as well and is just screwed on. However during installation, it might get stuck a little tight.
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Tuesday, February 24th, 2009 AT 1:05 PM
Tiny
KC0DXH
  • MEMBER
That was the piece of information I needed. Thanks so much! It unscrewed surprisingly easily with a vice-grip. No muss, no fuss.

Now I just need to locate a replacement, but I don't think that will be a problem. Two parts stores nearby say they should have them.
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Tuesday, February 24th, 2009 AT 1:24 PM
Tiny
KHLOW2008
  • EXPERT
Cheers. Should you have problem getting them, which I doubt so as it should be readily available, you can try the local scrap yard. Should be plenty there and it is a generic item which you only need to get the correct length and metric size, does not matter what make.
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Tuesday, February 24th, 2009 AT 1:31 PM

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