You have 3 choices. Have the car towed to a shop with the tools to remove the bolt, buy a replacement manifold and install, or buy a few tools and remove the bolt yourself.
Sears and others sell bolt extraction bits. You can use the remaining bolt to size the needed replacement. The remaining bolt is also useful to determine depth so you do not drill into a water passage. Once you determine depth some mechanics will use a socket or something to fit around the drill bit to limit the depth the drill bit can travel. You would then need to drill out a hole in the busted bolt so you can fit the extraction tool inside the newly drilled hole.
Sometimes it is smart to buy an extra drill bit or 2 in case you snap what you are using. Then you may consider that you are doing what you pay a mechanic to do. If this messes up the mechanic will still charge you for a manifold and labor to replace.
This can be a little repair with skill and luck or escalate into more. There has to be a reason for the bolt to fail, perhaps someone used Locktite on the threads at last repair.
SOURCE: Broken bolt housing for thermostat gooseneck cover on intake mani
Hello, The only thing you can do is weld the broken area and the drill and tap the hole.
Go to http://www.durafix.com/ and they have a solution for you. Good luck and let me know how you make out.
SOURCE: what is torque spec for 2004 Ford 4.0 thermostat
Normally these bolts are about 20-24ft lbs. You don't want to over tighten them as they should have a rubber washer/gasket to help provide a good seal. These cast aluminum housing will easily strip so just use care when tightening. Just snug both bolts and run the vehicle til it reaches operating temp then check for leaks. You can also purchase a Chiltons/Haynes manual for your vehicle at any auto parts store for $15 they normally give you the torque specs as well as some other valuable tipe
SOURCE: torque wrench settings for ford focus thermostat
There is a set spec, but for the DIY mechanic,,
Using a !/4 " drive, with the correct long socket, apply a FIRM effort on the wrench, but obviously not too much, as to sheer the studs. Always use a NEW gasket on all mating surfaces.
Regards,DT
Testimonial: "a specific torque setting would be better !!"
SOURCE: How do you remove a
This is easy if you have enough of the old bolt sticking up. You will need a good sized hammer, a very good set of vise grip pliers (round teeth not the flat teeth type). Now hit the bolt end with the hammer hard, hard enough to flatten the top of the broken bolt, but not hard enough to break the T-stat housing. Then you can spray some wd-40 on the bolt. Now clamp the vise grips on the bolt end. work back and forth back and forth to get it loosened. Then you can try and turn it on out. Hope this helps FixYa up.
Testimonial: "Thank you so very much!"
This is an easy repair.
Fig. Exploded view of the water pump-2.3L engine 
Fig. Using Special tool 303-S455, or equivalent, remove the coolant pump drive pulley
Fig. Using Special tools 211-185 and 303-S455, or equivalent, install the coolant pump drive pulley370 views
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