Here is a little write up on how to remove the ever-so-common broken exhaust manifold stud.
The work and procedures shown and described in these world-wide web files are intended for use by people having average skill and knowledge of the subjects. Caution: If you are inexperienced in using any of the tools or equipment depicted or any of the procedures described, or are in doubt that the work and procedures shown and described may not be safe in your chosen situation, consult a person skilled in the performance of the work or procedure. Throughout this information there are specific safety recommendations given, please pay careful attention to each of these. The creator of the information in these files disclaim any liability for injury or damage arising out of any failure or omission to perform the work or procedure shown and described. The creator of the information in these files disclaim any liability for injury or damage arising out of any unsuccesful or successful attempt to perform any of the modifications or "DIY" projects and tasks outlined within this thread.
Liquid penetrating oil
Drill with 1/8" bit
No.1 screw extractor - $2.99 at Sears
Now that that is over with let's get started!
(RED CIRCLED header bolt broke)
1. Remove the exhaust manifold and soak the broken stud with liquid penetrant.
2. Use a center punch and tap a pilot hole in the broken stud.
3. Drill a 1/8" hole in the stud. Take your time and don't push too hard. Be sure to use a liquid penetrant as lubricant so the drill bit will not overheat.
4. Tap in the "screw extractor" or "easy out ( EZ-OUT )" with a hammer. Make sure it is snug.
EZ OUT sets:
Sears Combined Screw Extractor Drill Bit Set:
5. Unscrew the broken stud with a pair of vicegrips attached to the extractor. Use lubricant if needed. Here's a pic of the broken stud removed.
PROBLEM: the drill bit was VERY difficult to sit in the middle of the broken bolt. i managed to get the screw extractor in, but when i turned it, it just ripped right through the bolt.
Quote: dwnthehatch reply
I had the same problem the first time I did it. You need a sharper drill bit. And drill deeper.