Well, the saga continues...still trying to get this '95 Country (147k miles, previous history unknown) ready for winter so a cooling system refresh seemed like a good idea. That is, right up until one of the water pump mounting bolts broke. I've tried visegrips, the left-hand thread bolt removers, and drilled a hole for an extractor which didn't grip (I didn't quite get the hole centered, which may have caused it to fail). Before I cut this thing off flush with the block and try again with an extractor, is there anything else I should try?

 

heat the **** out of it

 

I agree heat it up a bit .

 

Yup, X3. Heal the hell out of it and use your vice grips and twist like hell. That is the best, easiest, and quickest way to remove these bolts. Isn't it amazing how common it is for previous Jeep Owners to take horrible care for their vehicles?

 

If you don't have a torch handy, try spraying it with pb blaster. Let it set for a few minutes then hit on top with a hammer ( like your trying to drive it into block). Then try vise grips again. Might take a few tries but I have found the very effective in many situations.

 

Heat it and spray it with PB blaster numerous times. The heat will help suck the penatrating oil in and then work it back and forth. Good Luck.

 

I know there is not much room....smack it good on the end, preferably with a pall-peen. The shock and maybe some slight distortion will help break it loose. Also with the vice grips try it a tad IN as well as out. Also torch the STUB, (don't think you would want to get the head too hot). Get it good and hot, then PB, then let it cool some and smack it. Use the largest extractor you can. If you break a one in there.....you know.....that REALLY sucks.

 

Heat it up and let it cool through 3 cycles. When it has cooled down the last time, it will probably screw right out. I have no idea why this works but an old mechanic taught me this trick 15 years ago and it works well.