So, I was swapping out the IAC on my 302. I soaked it with PB Blaster. But I still managed to break an 8mm bolt. Should I try to tap it out or should i just eat the bullet and find a new TB. I never had to tap a bolt out. What are your thoughts?

 

Happened to me too. I just drilled it out and it was fine

 

What size bit did you end up using? Did you use EZ out or had to re-thread?

 

I was lucky enough to just have to drill off the head. Then I took a pair of pliers to get the rest of it out

 

I tried taking the broken bolt out with zero success. I tried vise grips and Channel Locks, just ended up chewing it up. I guess, I can ask my neighbor to weld a nut on top of it, but he is not home. Anybody have any suggestions to get this bugger out of my TB?

http://www.flickr.com/photos/sst_photography/11537369683/

 

Have tried heating it up, just not to much heat. If that does not work. Use a 7mm or 6.8mm drill and drill it out. Most autoparts stores have drill and taps packaged together there is enough metal to go up to a 8.5mm or 9mm bolt. But the heat should work. Then boil the TB and clean with a brush. When you put everything back together use BLUE loctite. Also check your bolts that connects your upper and lower intake. Ford seems to have trouble with them staying tight.

 

I got her out with lots of heat. I just used a small newer (sharp teeth) vise grip and a regular propane torch. I clamped the vise grip to the bolt and heated up the area for a minute or two. Lo and behold the broken bolt started to turn. Woohoo.