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What the best way to remove seized head bolts

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First try bashing the bolt head straight downwards. This may loosen the corrosion in the threads. Take care not to hit surrounding structures.

Next try a large impact wrench (you can hire them) with a high strength socket which is a good fit. Take care the wrench is set to run in the undo direction.

Posted on Apr 21, 2015


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IF it broke off while tightening , drill a hole in the center and use a easy out tool to remove it . if it broke off while trying to remove it the tool will likely not work as it is seized , you will have to use a drill for that size thread and tap in a new thread , best left to a pro.

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Replacing spark plugs on a 2004 chevy malibu

2.2L Engine
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    Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine.
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WARNING Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result.
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They are a pain in the *$&#$^ to get out, here's what you need to do:
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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.

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