jbhashem

Hi All, My 22re (88 pickup) with EFI has a problem that I gave it. A simple thermostat replacement turned to a broken bolt, followed by bad drill out, resulting in large hole in aluminum (7/16"). Now, I cannot get a seal with water outlet and intake manifold. A mechanic said I needed to repace the lower intake manifold. Is this totally necessary? He said that it cannot reach it to welded it shut (no problem for future since if therm ever goes bad, THEN I replace the intake manifold). He also said heliocoil won't work...Thoughts? Thanks John

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Elton

i would say just go to a junk yard and pick up a intake manifold

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My Truck 98 4runner SR5 3.4L 5spd 4x4 E-Locker Mods
Mom 07 Tundra d-cab limited 5.7L 4x4 auto
sister 92 pickup SR5 X-cab 3.0L 5spd 4x4
Papa 89 Pickup SR5 X-cab 4x4 3.0L 5spd/98 4runner SR5 4x4 auto 3.4L
R.I.P 91 4runner SR5 4x4 3.0L 5spd Totaled 5/13/06 My Wreck

trythis

oof, I did the same ,but the drill out went better than that. I second the junk yard approach.

wrenchmonster

Hummm. Do you have a picture. Although not a good idea overall, could you get away with some epoxy and a keen-sert? I don't think the torque spec is very high for the stat. Por-15 has a few epoxy products and even an aluminum paste I believe.

Could you tap out and use a slightly larger bolt to hold the stat housing? Are there threads deeper than the original bolt? Could you catch those threads by using a longer bolt? How about a weld up and re-tap?

I'm not at all advocating a shoddy repair, but just trying to brainstorm some possible ideas.

jbhashem

Thanks for the great ideas. I don't have a pic and truck is at a shop. I will look into some of the products discussed. I used cold weld but the vibrations of the engine are too much for the weld to hold. I can fit 7/16 in but have been unsuccessful at tapping new threads. But, it is probably worth to try again.