1996 with 150k+ miles. I was really hesitant to attempt this level of a repair myself but I read everything I could find on here and watched the youtube videos and decided to try it. Everything was going really well until this morning when I was installing the new WP and broke the head off the upper bolt. BTW, don't anyone pay attention to the torque settings in Haynes manuals, they're obviously wrong.

Now, I know I need to drill out/use an extractor on the remaining piece of the bolt, but what drill attachment or right angle drill and bit will fit between the frame rail and the bolt? I have about 4" to work with and all the attachments and right angle drills I've seen are too deep. Any suggestions would be really appreciated.

And it's broken off flush with the hole so no chance of welding on a nut I don't think.

 

Nothing that I have ever seen. I read on here someone was able to pull the CVs, disconnect the exhaust and most of the motor mounts, and rock the engine low enough to get at it from the wheel well. IIRC the ears of his pump broke off, so he attached a slide hammer and popped it out.


This is by far redneck engineering, but the purpose of the bolts is more to press the pump into the hole straight. Yes they hold it in place, but it does a good job of that on its own. If I was in your shoes (without the tools to pull the engine, or the money to pay to get it fixed), I would try to find a way to press it into the hole and use the two remaining bolts to hold it in. I did this job earlier this year. I was afraid I was going to strip the threads trying to get the pump out. If you can get it in, the two bolts will hold it fine. Find an expander of some kind and use it against the frame.

 

Brilliant, Finkle.

Thanks

 

You can tilt the entire engine by removing the passenger side motor mount and the y-pipe and center subframe support.

I had a similar problem with the water pump and needed to use a helicoil to do the repair.

 

What Finkle said should do the trick as he did it himself.
I was going to suggest dremel a flat slot into the broken stud and use a short stubby flat head screwdriver to get it out.