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#1
08-26-2013, 05:14 AM
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Do 606 thermostat housing bolts tend to break?
Need to change t-stat in my 95 E300D. Am somewhat alarmed by how many people have the experience of breaking the housing bolts....but think most of what I read was with 617s. How are 606s in this regard?
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14 E250 Bluetec 4Matic "Sinclair", Palladium Silver on Black, 159k miles 06 E320 CDI "Rutherford", Black on Tan, 178k mi, Stage 1 tune, tuned TCU 91 300D "Otis", Smoke Silver on Tan, 145k mi, wastegate conversion, ALDA delete 19 Honda CR-V EX 75k mi Fourteen other MB's owned and sold 1961 Very Tolerant Wife 
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#3
08-26-2013, 08:54 AM
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use lots of penetrating oil before you attempt this task. If the previous technician used "grunt torque" to tighten those little bolts they will break off.
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2012 BMW X5 (Beef + Granite suspension model) 1995 E300D - The original humming machine (consumed by Flood 2017) 2000 E320 - The evolution (consumed by flood 2017)
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#4
08-27-2013, 08:22 PM
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There is more, if the thermostat gasket is weeping ( you won't always see liquid ) the bolt threads will become corroded / stuck to the hole threads.
If the bolts are in through holes, wire brush where they stick out, use penetrating oil and _let it soak_, it didn't corrode in 30 seconds and anything you spray on won't soak in that quickly either. Tapping on the bolt head helps to wick the oil somewhat. A bit of heat on the aluminum helps as well ( like heat gun .) Start to turn the bolt, it is hard to describe what a "I'm stuck going to twist off" bolt feels like so I can't help there. If the bolt starts to turn then gets tight, stop / reverse direction but don't turn until tight, try to remove again but stop before the bolt becomes difficult to turn. What you want to do is use the free play and work the bolt back and forth breaking free corrosion. However, this leads to fatiguing of the bolt and it may break off where removing in one shot ( still hard to turn ) it wold survive. Removing stuck bolts is somewhat of a black art. Removing broken stuck bolts full on dark side. Sometimes there is no way around breaking a bolt or damaging something. Remember broken bolt extractors generally have less strength than a full size bolt. The _ONLY_ broken bolt extractor worth purchasing is made by Ridgid, it is a straight spline 2 to 3 inches long and a nut to drive it. This gives you the ability to turn in both directions ( remember the "free play" to work it back and forth breaking corrosion ) I've even gone so far as to cut housings away to relieve through hole corrosion / gain access to the top portion of threaded hole.
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