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Need to remove a broken stud bolt from aluminum head without drilling

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Are you in a tight spot and can't drill?

Posted on Jan 18, 2013


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Exhaust manifold bolt broke off into head, is there anything I can use to temporary fix it.

no temporary fix
the real fix is to remove the manifold , drill and use an extractor tool to remove the broken stud
however if the stud is at the end of the manifold , consider this
many exhaust manifolds do not use a stud at the ends

Oct 11, 2017 | Cars & Trucks

1 Answer

How do you remove a broken head bolt?

I would centre punch mark the centre of the broken stud and with a drill stand, drill a hole down the whole length of the stud, getting larger and larger as I change the bits. When I reach the last threads peel the thread out using a pick. If the thread is damaged, drill oversized to tape to fit a Hellicoil.
The largest Essex Engine was 3.4litre V6, not 3.8. The most common was the 3.0litre fitted to the Zodiac and Capri. It was a V4 with two more pistons and uses the same head bolts etc.

Jun 18, 2017 | Ford Cars & Trucks

3 Answers

I have a 2003 Ford Ranger 3.0 and I have an exhaust manifold bolt that has broken off inside the manifold,and the evaporator coil,and other AC parts are in the way .what options do i have on this

With the exhaust manifold off. If there is some of the bolt sticking out. You'll need a torch to heat the head up, red hot around the bolt. Also a pair of needle nose vise grips to grab it with and turn it out. You'll have to heat it several times to get out. No bolt showing, you best bet it to pull the head. Drill the bolt and extract it.

Jul 26, 2016 | Ford Cars & Trucks

1 Answer

Thermostat housing

I think I would try to heat the area of the head around the broken bolts with a torch and then try to work out the broken bolts with vicegrips if you are able to get on them. If not I would think about seeking professional help. Trying to drill into a steel bolt in an aluminum heat can be disastrous.

Apr 28, 2013 | 2005 Toyota Corolla

1 Answer

Studs for a exhaust manifold rusted off flush with the head. I tried drilling a giude hole for easy outs but the drill bits walked off the center of the studs. The bit chewed into the head and made a hole...

If you have a welder and a torch set you can still get them out. take a 3/8 nut put it over the broken bolt and weld it together. then take the torch and heat the nut and head up. you need to heat these up to a glowing red. then start removing the bolt. go back and forth if you have to. good luck. ps if you don't have the tools remove the head and take it to a shop

Jun 18, 2010 | Cars & Trucks

1 Answer

Exhaust manifold leak due to broken bolts, how do I remove these bolts from cilinder head

If it's broken off below the surface you'll have to drill the remainder of the bolt out. If it's broken off above the surface and you're somewhat handy you can weld a nut on the end of the broken stud and remove with a socket wrench. Here's an excellent read on the how to of removing broken saves me the time of having to type it all out. Good luck.

Jan 07, 2010 | 2001 Ford F150 Styleside SuperCrew

2 Answers

I have a 1999 Durango that had an exhaust leak on cylinder 8. the manifold bolts were so badly corroded, I had to cut the heads off and unscrew the studs... except for #8 cylinder... the bolts were both...

It can be a daunting task. You'll need to center punch them as deeply as possible. Use left handed cobalt bits starting with the smallest possible bit & work your way up to about 3/4 the size of the bolt & try an easy out. Don't break the easy out!! If the easy out fails,continue drilling to the proper size for a heli-coil & install one. Use anti-sieze on the new bolts. If this fails,hate to say it,remove the head & try a drill press.

Jul 13, 2009 | 1999 Dodge Durango

1 Answer

Header tried solutions offered previously

First, is the head off or is the bolt easily reachable? Your problem is common. The bits may be snapping because you are either pressing too hard or are changing angle while drill is in motion. The best thing you can do is first make a bit guide...Take a piece of steel at least 1/4" thick that is long enough to reach two adjacent bolts (use manifold as a template) drill both holes to the size of the studs. The one for the broken bolt should be substantially smaller and centered over the broken stud. Drill first with a bit of the same size you used to make the pilot hole. then go up to a size just slightly smaller than the stud, so threads are not damaged. I like using a reverse twist bit for this because the drill force and heat caused by drilling will often back the stud out. But those bits are hard to find. after the hole has been drilled, use a straight type thread remover (not an "easy out" ...they spread the stud and exert force against the threads actually making removal harder) straight type removers look a lot like torks bits and are tapped into place creating grooves that help turn the stud. you can apply some heat to the area, but generally just turn the stud out slowly, use lots of solvent and after each turn out, run it back in to clean the threads and prevent binding. Funny...It takes longer to write this than it does to actually do it!!! When replacing, put anti-seize compound on the new stud.
Good luck! Don't drive with broken will warp the manifold.

Apr 09, 2009 | 1994 Pontiac Firebird

1 Answer

Exaust manifold replacement

Stud removal can be either very hard or easy. Just depends on how hard access is to the stud. You will need to center punch the broken stud. Then use a very good high speed steel drill bit to drill a pilot hole in to the stud. Tap an easy out in to the hole you drilled into the stud and hopefully it will break loose. Worse case scenario is you might have to remove the head and use a torch to heat it for removal or actually use the torch to blow it out of the hole. If you must remove the head and need to use a torch to remove the stud send the head out to a good machine shop. These shops have people there that are qualified to do this process. To much heat can damage the threads in the hole or ruin the head. Good luck. If you ahve more questions please feel free to ask.

Mar 05, 2009 | 2001 Ford F250 Super Duty Super Cab

3 Answers

How to get a broken bolt out so i can put on the harmonic balancer

Hi poohbear
You will need to use thing called an "easyout" or  "eziout" 5c4e174.jpg
you have to drill the center of the broken bolt, then gently hammer in the eziout, to then wind the broken stud loose. You may notice that the eziout has the reverse direction thread, so the harder you wind it out, the more it winds into the broken bolt. Use plenty of penetrating oil about the stud, even let it soak for a bit. Just don't break off the eziout, they are super hard, and you will not be able to drill that one out. You can buy then from most hardware stores. Messy, but the only real way to get the the problem solved.I hate it when a stud snaps, it happens all the time, usually the last one to be undone.  Good luck. 
regards robotek

Dec 19, 2008 | 2005 Jaguar X-Type

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