Went to remove egr valve from throttle body and bolt head snapped off. Removed throttle body and tried to remove bolt with vice grips. No luck. Does anyone think it would hurt to use heat on the aluminum body to help or drill ,tap, and larger bolt or drill it out and put a nut on the back? Ideas. It is on a 97 f150 4.6 v8.

 

If there is enough threads exposed, I would chase a nut on it and then weld it.

 

It doesn't even need to be showing any just get a nut big enough to weld inside but small enough you don't weld to whatever it's in.

 

I'd first attempt to drill it out and tap the hole. aluminum is a different beast to work with than steel is. With that noted if your interested in trying heat...

Carefully heat whats left of the bolt, NOT the aluminum body, cycle it a couple of times between red hot and cold. Again, NOT the aluminum, but the steel directly. then try to extract it, failing that. Your hooped. Don't be surprised if you still have to drill and helicoil the hole if you manage to get it out, the steel has galled to the aluminum and is going to a bitch to remove in any event.

 

 

Not sure what this face is for. What he is mentioning is a common method.

 

Got it. Two heat cycles and two pair of vice grips. Thanks guys.