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Broken Thermostat Housing Bolt in Cylinder Head

Old Nov 26, 2018 | 12:26 PM
  #16  
PatHenry's Avatar
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From: Groton, MA
Year: 1995
Model: Cherokee(XJ)
Engine: I6 4.0L
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Originally Posted by NRGXJ
Thanks! I foudn these specs:

The thermostat housing bolts are 1 inch and 2 1/4 inch long.
The diameter of the shaft is 5/16"
Thread pitch is 18.
Hex head uses 1/2" socket size not 13mm

I believe the torque is 13 lbs. But still have to confirm.

I ordered the bolts on EBAY here:
5/16-18 x 2-1/4 Grade 8: https://www.ebay.com/itm/262064263214
5/16-18 x 1 Grade 8: https://www.ebay.com/itm/252102719480

Will update everyone to see how it goes.
Your local Ace Hardware will have those bolts if you don't want to wait.
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Old Nov 26, 2018 | 01:14 PM
  #17  
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From: Manlius, east of Syracuse, NY
Year: 2000 XJ Sport & WJ Laredo
Model: Grand Cherokee (WJ)
Engine: 4.0L
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You're right. I went out and checked BOTH of my jeeps and you are correct. 1 bolt goes thru a thick part and the other is only thru a flange. I've been working on Chevy small block too long and my brain is still seeing 2 short bolts. Trust but verify! Damn! I went out in the pouring rain in just a T-shirt and am now cold and wet. The things you guys put me thru....just kidding.
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Old Nov 26, 2018 | 06:26 PM
  #18  
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From: NY
Year: 2001
Model: Cherokee (XJ)
Engine: 4.0 i6
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Originally Posted by dave1123
You're right. I went out and checked BOTH of my jeeps and you are correct. 1 bolt goes thru a thick part and the other is only thru a flange. I've been working on Chevy small block too long and my brain is still seeing 2 short bolts. Trust but verify! Damn! I went out in the pouring rain in just a T-shirt and am now cold and wet. The things you guys put me thru....just kidding.
Ha, I feel you Dave!

Odd thing (as I wait for all my bolts to come in next week). I have a 2 1/2" hex bolt laying around and tested that on the flange with a 1" bolt, both have threads that stick out the SAME distance from the flange: 5/8" of an inch. Which means if the top is speced at 2 1/4" then the top bolt threads into the engine 1/4" LESS than the bottom bolt.... I can't confirm the full length of my broken top bolt yet as it is still in the engine. Wondering if it should be 2 1/2" instead? ... Will have to wait until I take the broken bit out to confirm its length.

Raining here today and can't wrench on the Jeep. I work on the streets with no garage!
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Old Nov 28, 2018 | 04:11 PM
  #19  
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From: NY
Year: 2001
Model: Cherokee (XJ)
Engine: 4.0 i6
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GOT THE SUCKER OUT!!!! 1/8" left-hand drill bit from
DRILL HOG USA DRILL HOG USA
saved the day! THANK YOU so much, everyone. So relieved! Was easier than I thought. I admit I was freaking out!

Waiting for my bolts now from Bolt Barn on Ebay.
and my Stant Superstant 195° thermostat
*** I CAN CONFIRM BOLTS SIZES ARE: upper: 5/16 - 18 x 2 1/14" and lower: 5/16" - 18 x 1"

Using a Fel-pro gasket.


Last edited by NRGXJ; Nov 28, 2018 at 07:37 PM.
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Old Nov 28, 2018 | 09:41 PM
  #20  
OldTires's Avatar
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From: Eastern Long Island, NY
Year: 1996
Model: Cherokee
Engine: I6 Cyl / 4L
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Old Nov 29, 2018 | 08:26 PM
  #21  
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From: Evart,Mich.
Year: 2001
Model: Cherokee (XJ)
Engine: 4.0
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I always have good luck with the left hand drill bits Glad you got it out always love it when a plan comes together!
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