I was using an in/lb torque wrench to make sure not to over tighten, but the plastic bolt head snapped off. Now what to do in this difficult spot? Should I take the radiator out? Is that difficult? Anyone have a procedure on that? How about experience getting the bolt threads out? An extractor won't work since there is about 6 inches to the bolt through the frame (my reason for thinking the radiator needs to come out). Any suggestions welcome!!

In the final stage of the Intake gasket replacements and now this errrr

It'* tight right? Don't touch it. Next time you have to drain it, do what most others do, disconnect the lower radiator hose. Reason why most do this is either sediment in the radiator makes the plug not drain or the plug aims to break and there'* an easy way to bypass it.

Other than that. You could pull the radiator, fight the plug out and hope to find anotehr one in the help section of the parts store.

I never use the drain plug to drain my rad. If it isn't leaking, leave it. Like Bill suggested remove the lower rad hose.

I always remove the lower radiator hose to drain the radiators on my cars, the GP still has the original one, and the drain plug was snapped off before I bought it.
When the radiator decides to leak, I'll install the oversized one I put aside for it.

I know guys but it just feels wrong! Guess there is now easy way...but I may try an oversized screw driver and heat it up. There is a hole bored inside the plastic bolt, with the threads to the outside. Thinking if I heat the screwdriver and push it up into the hole enough for it to mold to it...I might be able to back it out and install a new one. It is just too far above the frame to get an easy out on the thing, or it would be a much simpler task!!

I sense an "Oh damn, what did I do that for?" in your near future.

Is it possible at all to get a pic of it?
If I could see what is left of it I could possibly think of something, I thought of heating something up to make two holes in it to turn it with something like 2 picks, but if it is broken off how I'm thinking, that would be challenging to do without messing something up, like say you push the picks in to hard/too hot and go too deep, you do not want to pierce through the radiator.

If you do get it out then here is the link I put in the other thread for the part you need to replace it, it is part #18
http://parts.nalleygmc.com/showAssem...modelYear=2002

I have heard of issues some can have when draining their coolant through that, but don't feel bad, I have always used it, and always will as it has never given me a problem, I put a little silicone on the o ring that is on it and I hand tighten it when done draining the radiator, so far I've never had a leak.
I only remove the lower radiator hose if I am totally flushing out the system, as it is easy to hook a shop vac to it and get most of the coolant out of there pretty quickly.

Given that it does not leak, and you can easily drain the coolant from the lower rad hose the next time you service it, it may just be best to leave it as is as Bill suggested.

Well I just wasn't satisfied leaving it alone. And I know that really was the right thing to do...but...lol I decided to take a flathead screw driver that was slightly oversized for the hole down the center of the bolt. Then I heated it and tapped it in with a mallet (only slightly) and then I waited about 10 minutes for it to cool. The plug backed right out. YAY! I know I was taking a chance, but I needed it to be correct since this car will pass along to other family members. Thank you William for thinking out of the box. That is what remedied my problem! Thanks All!!

This kinda cracks me up because I work on a lot of people'* cars for cam swaps and modifying. I see a non-broken drain plug about 1 in 10 cars.

Glad it worked out well for you. I understand teh desire to know it'* right.

I had a feeling you'd not let it go, I am the same way, I usually cannot leave something alone if I think I can fix it, I have found that usually persistence pays off, as it has in your case.

Congrats on sticking with it and getting it out of there!
And you are very welcome, glad I was able to help.