I feel like those two ports are begging me to use them for coil leads, and turn it into a little electric heater. Totally overkill, but could be a fun project for an hour or so.

 

This just happened to me too when I replaced all my coolant lines and TBH plate this weekend! Went to screw the new one in, and it just didn't catch any thread. And the old screw that came out was all gummed up and rusty.

I already ordered a replacement throttle body for like $30. Good to know I can just bypass it in the mean-time (or forever, I suppose). Winter won't get serious here for at least a few more weeks.

 

So I had the dreaded throttle body heater leak this summer. I debated about bypassing it vs replacing it but since I live in Minnesota and need my Disco in the winter I decided to replace. In the process of removing the throttle body, the bolt head closest to the heater plate snapped right off. This is one of the bolts that attaches the throttle body to the intake. I’ve been trying to get this bolt out for days now. Soaked it with liquid wrench, PB Blaster, etc. applied heat nervously ( don’t want to melt nearby wiring or catch something on fire!) used vice grips but it will not come out. I’m guessing the leaking coolant really soaked the threads and welded it in the intake good.

Any suggestions? Should I just bite the bullet and drill this out and retap for a larger bolt? Any chance just using 3 bolts will give enough of a seal on the throttle body-intake gasket?

really wishing I’d just done the bypass!

 

You definitely need all 4. Is there any way you can dremel a slot in the bolt to get a flat head screwdriver on it, without damaging the TB?

If not, you could carefully try a small sized extractor bit. Maybe just staring that process will be enough to break it loose. Just be really careful not to damage to TB threads, or you'll be "screwed"... See what I did there?

 

Or ...

The most efficient solution may be to replace the intake. Yeah, that'll cost a few bucks, but depending on whether or not you have a boneyard near you with a DII it may be the best route. Or check with Abran, Paul Grant or Will, or check eBay.

 

Here is a picture of the broken bolt. I may try a bigger vice grips, the ones I have don’t seem to get a good bite on it and slip off to easily. If that fails I’ll try the extractor. If that doesn’t work I’ll drill it out there seems to be plenty of meat on that bolt flange to retap for a slightly larger bolt. Actually looking at the photo I bet there is enough clearance on the backside of the flange to just drill out the bolt with a smooth hole and through bolt it with a longer bolt and a nut.

Replacing the intake would definitely be my last resort.

 

Just replace the throttle body. Its quick. I have a couple on the shelf.

Use antiseize on those bolts.


Nevermind....I thought the heater was stripped out...you'll need the upper intake...which is also pretty easy...I have a couple of those too lol.