Escalation from replacing thermostat

[rsowersby]

I replaced the radiator in my 1999 Mountaineer with 5.0L V8, and then was replacing the thermostat as I had heard was recommended. I could not manage to get the right lower bolt for the water pump housing tightened enough, so after trying for several hours, I called the neighborhood shop. They sent a couple of guys over who, after trying themselves for about half an hour, showed me that the bolt had broken off. They told me that they could have it drilled out and replaced for about $75. I had it towed to their shop to get repaired. Today they called and said that the bolt had lodged in the intake, so that the intake had to be replaced; with labor, parts, fluids, etc., it would be about $450. Does this sound reasonable? I think they might be trying to con me. If anyone knows anything that would help me, I would appreciate it. I am a novice. Thanks.

 

[1998Exp]

Are you talking about a water pump bolt or a thermostat bolt? You mentioned replacing the thermostat, not the water pump. The water pump bolts to the block through the timing cover, so I am guessing you meant the thermostat bolt.
With the intake off the vehicle, they should be able to yank that bolt out, but if they can't, the lower intake manifold alone is about $300, so $450 looks more than reasonable.

 

[rsowersby]

I'm sorry, it is the thermostat bolt that he said was "fused" to the intake. That just seems odd to me. What started as a simple "drill the bolt out" operation has escalated into a major intake replacement. Is this feasible or am I being duped?

 

[OneLever]

It sounds like you are being duped.

The bolt in question is on the lower, left side as viewed from sitting in the driver's seat, which secures the thermostat housing to the lower intake manifold correct? The bolt sheared off inside the hole on the lower intake manifold?

If so you should be able to extract it and re-tap the threads for a size larger bolt. It sounds like you were tightening it without a toque wrench and over did it.

 

[windsors03cobra]

If they are half assed mechanics or things went horribly awry for them I have no idea why they just didnt drill that little 5/16-18 bolt out of there and either retap it to that size or maybe go to 3/8-16. Seems like there is plenty of meat there for that.
With all the crap out of the way its pretty accessible, sorry to hear things are going this way for you.