StubbornPatriot wrote: ↑Tue Apr 04, 2023 8:19 pm The mechanic I used to recommission my 220 Turbo managed to snap all the bolts and couldn't get the pump off the housing anyway as they were too firmly corroded together. After his fruitless search for a used replacement housing he then suggested a new one from Rimmers, at some extortionate price. I asked him if I could take it with me as a pattern when continuing to look for a used one. Once home, during my lunch break, I managed to separate off the old water pump using a robust wide bladed wallpaper scraper, caution and a bit of physical persuasion. Not a mark was made on the housing mating face. After heating the housing up with a blowlamp and giving a good drench in WD40, I then tried getting the remainder of the bolts out using the 2 nuts tightened together technique, but only one would come out that way. The remaining bolt stubs had enough on them to get molegrips on. Using as big a pair as possible and clamping them extremely, extremely hard down (both hands on the clamp bar) I managed to remove all the remaining broken bolts. Re-heating and WD40ing as required. I then cleaned it all up and took it back to the mechanic. At first he thought I'd found a good second hand housing. Upon explaining that this was the one I took away with me, he asked me if I was looking for a job (and I'm not convinced he was completely joking). He was, however, a little embarrassed.

So, even if bolts do break, it's not necessarily the end of the world.