Best method for extracting broken exhaust manifold studs?

[OhioGuy36]

Besides welding or pulling the motor and putting new heads on?

Sent from my SM-G975U using Tapatalk

 

[PuffTheMagicDragon]

Use an easy out. Basically drill a little hole in the sheared off bolt (careful NOT TO drill at an angle into the threads) and then screw in a reverse threaded easy out and it backs it out. They sell kits at Lowes/Home Depot/Harbor Fright.

 

[Tim Garceau]

Don't even mess around with extractors if it broke near flush, even a 110V Flux core MIG is better option than breaking an extractor or drilling into a water jacket. Most don't own a compact right angle drill and there are several bolt positions that leave minimal room for error.

Weld a .060" washer to the broken stud, then weld on a nut having slightly larger ID than the washer. You can even tack on the outside of the nut if you leave minimal protrusion allowing a 2 flat grip with an open-end wrench to break it loose. Then roll it out like butter.

You can also try the bees wax method with a torch but I didn't have time for that test either.

 

[LoneWolf3574]

This guy on YouTube (South Main Auto Repair Channel) has perhaps the best way to remove broken manifold bolts. If you can avoid it, try not using extractors, if they break off, you are boned. I've been there, done that, and paid a pro to fix my mistake.

 

[RoadRamblerNJ]

You ask for the best method (welding on a washer & nut) and then your next sentence rules the best method out.

Don't be afraid to weld it up or pay a guy to do it. Far less can go wrong. There is a reason most of us old guys don't have any of the "smaller" E-Z Outs left.

 

[JB1]

Here’s a nice tool to help weld a nut to the stud

https://ezstudout.com/

 

[Tim Garceau]

You might as well just send a programmed robot out there with the kit to finish off the entire process.

 

[Cowboy770]

DO NOT USE EZ OUT!!! Lisle makes a jig that allows you do drill it straight. I recently Bought it after a broken ez out broke off on the broken bolt and spent 2-3hrs grinding it out with a dremel.

 

[LoneWolf3574]

DO NOT USE EZ OUT!!! Lisle makes a jig that allows you do drill it straight. I recently Bought it after a broken ez out broke off on the broken bolt and spent 2-3hrs grinding it out with a dremel.

Lisle part number or link amigo?

EDIT - NVM, I found it, Lisle 71500

https://www.lislecorp.com/specialty-tools/71500-manifold-drill-template-for-dodge-57l-hemi

 

[BWL]

Repost

 

[GTyankee]

 

[kevkev]

I used one of the bolts that came out, cut it down, put in vice and drilled straight through the center. I then threaded it in enough to use it as a guide for drilling for an easy out. Mine were snapped off nearly flush with the head.Even half a turn was enough to hold the guide screw.

 

[vdemarco]

I would use this method
Which basically is weld on a bolt and use that.

 

[DILLIGAF]

Weld and remove. Not hard

 

[LoneWolf3574]

This thread is 2 years old and the suggestions given were already given (Lisle and SMA video).

 

[kevkev]

W

 

[kevkev]

Whoops. Just replying to a recent post and trying to show a cheaper way that works.

 

[GTyankee]

Because of the subject, we may not be answering the original posters question
But it is a subject that comes up way to often

 

[beng3303]

Lisle part number or link amigo?

EDIT - NVM, I found it, Lisle 71500

https://www.lislecorp.com/specialty-tools/71500-manifold-drill-template-for-dodge-57l-hemi

This kit is genius! I certainly hope to never be in this position but glad to know someone thought out the solution!