Previous owner did some work and now I'm feeling the repercussions. I changed out the water pump and I accidentally cracked the timing chain cover. After we got that off, we found that a bolt had been broke off in the block, drilled/tapped, and at some point the ear of the hole had cracked too. Now I need to reinstall the timing cover but one of the holes doesn't have anything for the threads to catch.

This is on a 1995 F150 with a 302. I'm open to suggestions/ideas.

View image: photo (2)


It's the lower left bolt hole that is broken (in the bottom of the "Y" in the photo).

 

Are you saying a chunk of the block is broke off?
Might need a machinist to fix. Without seeing it if it were me I'd weld a nut on the block - fill missing area with welder - grind it down flat smooth to make a sealing surface. No real pressure or precision mechanics happening on a timing cover

 

Edit: added photo to the top post

 

I had the upper bolt hole problem . I used a cobalt drill bit and drilled into the water jacket in the block. Tapped a 5/16-18 thread and used 5/16-18 threaded rod washers and nuts w/sealant. It has been on my engine for 5 years . This is not an easy fix. The drilled & tapped the hole must be straight or it will not go through the cover and water pump. I have saved some blocks and Harley Davidson engine cases over the years. As Bakos said, You Might need a machinist to fix it ,if your not sure you can do it get someone that has experiance

 

Yes, it's on the right hand side but it's the lower/inner bolt, not the upper side. This bolt does go through the water pump and timing cover as well.

 

Yes, I saw that. As I said ,this is not easy. I start with a small pilot hole and make sure the hole is straight as I go up to the final drill/tap size. You have a tough one here guy. The ear of the bolt hole is broken off and it is best left to someone who has done similar issues before. Even, I would tell you I would do my best to save your block, But with this problem there's no guarantee

 

Tack weld a stud onto the block - put cover on and make sure it's straight - then tack some more - put cover on and make sure it's straight - then weld it - make sure all welding is inside and lower then mounting surface. Once again seems like ultra precision and super strength is not critical factor

Just a thought - if it sounds hokey just disregard

 

soco, Have you fixed your block or how are you making out ?