Broken Exhaust Manifold Studs

[Ironangel]

Trick to removing them?

[cdowns]

with a torch get it a bright cherry red and then try to grab it with visegrips and turn it out// if there is not enough sticking out to do it that way then i use reverse twist driull bits to drill them out and retapp the holes

[BLT gmc]

If you can grab it I agree with the heat and twist. I would also try a micro lubricant. Soak it well and keep it wet, the longer you keep it soaked the better. Maybe 2 - 3 days if you have the time. If flush or just short of flush, I use a grade three nut directly over the broken bolt and weld full, cherry hot with a wire welder. If the nut/weld break while trying to loosen,repeat the process. This time just try tightening the nut a couple degrees, sometimes this will break the rust bond better the bolt and the cylinder head. Then just wiggle back and forth. Hopefully each time it gets a little more loose. Finally the whole drill, left handed prefered, tap and possibly heli-coil. Good luck, Bruce

[Ironangel]

Right on, thanks you guys...I did try the heat method and twisted it right off flush! I did manage to drill a 3/16" hole through the broken stud and that thing is stuck tighter than dicks hatband! I'll go ahead and drill & tap a helicoil in it...Thanks for replies and help!

[slikside]

Originally Posted by Ironangel

Right on, thanks you guys...I did try the heat method and twisted it right off flush! I did manage to drill a 3/16" hole through the broken stud and that thing is stuck tighter than dicks hatband! I'll go ahead and drill & tap a helicoil in it...Thanks for replies and help!

Just to clarify, for future reference. it's not the broken stud that you heat to cherry red, but whatever it is screwed into. In this case, exhaust manifold/cylinder head. Heat expands metal, therefore you heat the metal surrounding the stud, then twist the stud out.

Don't mean to preach, but it sounds like you may have heated the stud itself?

[Greasey Harley]

Best stuff I ever found for stuck, busted off bolts: rapid tap cutting fluid ( you know, the stuff that's setting beside your drill press). Heat it up with a propane torch and drip rapid tap all over it. Get it f#@&king HOT! Rapid tap won't even smoke or burn. If you look closely, you should see tiny air bubbles coming out of the threads. Let it set for a couple minutes, then just spin it out. Seriously.
I like to use Snap-On baby talon pliers to grab a hold of the busted stud, if its out far enough ( those things are just as amazing). If its flush you'll have to use a left handed drill bit and an extractor.

I'm a boat mechanic, I have extracted A LOT of busted bolts.
Hope this helps, -Russ

[OldCreek]

I've had some success using "Drill Out" bolt extractor by Alden.

it uses a little momentum/speed as opposed to just a reverse tap….