How to remove Broken head studsI

[conor14]

I have two broken head studs and searched I think the double nut trick is the best way but how do I do it.. They're in there pretty deep! Does anyone have any pictures?

 

[viperlp01]

Are they broke off flush with the block? If so, first off good luck, second off the only way I have seen that attempted was with a reverse drill bit. You will need a very hard drill bit(cobalt or HSS) that you must order from snap on, mac tools, or a specialty hardware store.

 

[SlickPyro]

They are broken off down in the block? Like no threads are above the deck surface? If they are below the deck surface your best bet is an easy out if there are threads above the deck surface your best bet it getting a stud remover socket and using that. I got a stud remover/installer for my dsm needs. It's worked well on turbo studs and the exhaust manifold studs.

 

[conor14]

I didn't break them I found it while putting on my new exhaust, there broken inside the block no threads are showing what's an easy out?

 

[Tyeler18]

Those arent headstuds. Those are exhaust manifold studs. Headstuds would be a much more serious problem.

Vfaq.com has a good write-up on removing them, if I remember right you'll be drilling them out though.

 

[conor14]

K well now I feel extremely stupid.. I feel bad for wasting space and making this thread hahah Sorry guys!!

 

[AwD4g63TsI]

You're out of luck with the double nut trick if they're "deep in there"...that method only works if there are enough threads for two nuts to go on the broken stud. An easy out looks very similar to a drill bit, but it is cone shaped and the threads 'twist' backwards. You need to drill a hole in the center of the broken stud-then you can insert the easy out in to said hole on broken stud and 'unscrew' it. You'll need a very hard drill bit like cobalt(not the brand)-they aren't cheap. Best advice if you've never done it is to drill slowly and steadily with plenty of lubricant

I noticed that you said while replacing the exhaust--but you also said they were in the block, so I figured it might be head studs. Anyways,the easy out stuff still applies to the broken exhaust studs. You probably will need to helicoil them after your done I have a feeling.....I'll let you google helicoil on your own though

 

[99gst_racer]

It's pretty much impossible to snap off an ehaust manifold stud in the head. The aluminum threads will always pull out before the steel stud fails. Got a pic?

It's also incredibly diffcult to shear off a head stud. You'd have to be REALLY screwing something up in a bad way to make that happen. Glad to hear that's not your issue.

 

[kicker91laser]

Here is what I do, I have NEVER had this procedure not work for me:

First, soak the stud/threads with PB Blaster or similar.

Use a dremel with a small carbide bur and grind a dimple in the center if broken stud, be careful when doing this. I do this instead of using a center punch because the stud is usually not broken off flat.

Drill a small pilot hole, then step up to a drill bit larger enough for your extractor. I usually drill completely through the stud, you must be very careful not to drill into the head!!! Once you drill through the stud, you will feel the bit drop into the empty thread under the stud, stop there bofore getting into the head.

Once your hole is drilled, spray some more Blaster on it.

Using a decent extractor, remove stud.

 

[CrawlinZX14]

I think we need a picture of what's broken, because a head stud needs some serious torque to snap off in the block, and as stated, how would you snap a mani bolt off into an aluminum head? Next, why are you seeing head. Studs when your. Doing an exhaust job? I mean most of us have the head on the block when we are doing anything with exhaust. I have a sinking feeling he snapped the head off a bolt and wants to know how to remove it and did not phrase it correctly. And if that's the case, a double nut likely will not work unless its a threaded bolt all the way back to the head of the bolt. If it is, its quite simple. Thread one nut on all the way by hand. Then put a second nut on just enough to get a little thread showing above it. Back the first nut up to the second one and tighten themin opposite directions creating a jamb nut. Then use a wrench to remove said broken bolt. Not hard and you may need a better example than my explination, but gl either way.

 

[kicker91laser]

He has an exhaust manifold stud that has snapped, this is very common with these engines, especially on the outermost studs.

 

[Purple_Demon]

Yeah no biggie, easy fix.

get a small enough drill bit, drill your pilot hole. Then move up a size big enough for the screw extractor and drill that hole. Then TAP the screw extractor into the hole via hammer....and then just back it out of there. Ive done dozens of them on all kinds of cars from hondas to dsms and all the way up to chevy big blocks. All easy fixes.

 

[bryanwheat]

IF you have a welder on hand than weld a washer to the center of the bolt. Than weld a nut to the washer. This way works the best, if you don't have a welder than you are stuck drilling and using an easy out. I recommend heating the area around the bolt with a propane torch when extracting the bolt. IT will make the bolt easier to remove.

 

[Tyeler18]

It's pretty much impossible to snap off an ehaust manifold stud in the head. The aluminum threads will always pull out before the steel stud fails. Got a pic?

It's also incredibly diffcult to shear off a head stud. You'd have to be REALLY screwing something up in a bad way to make that happen. Glad to hear that's not your issue.

I find this very interesting seeing as how 3 of my 10 DSM's have had at least one snapped exhaust manifold stud in the head. All 3 had the farthest passenger side upper stud broken. One of them is sitting outside right now, but the manifold's on so I can't get an accurate picture.

He has an exhaust manifold stud that has snapped, this is very common with these engines, especially on the outermost studs.

^^ I agree. I see this on them ALL the time.

 

[Colt4G63 also]

They break all the time on all sorts of engines. The manifold expands and contracts more than the head, so the outermost studs are constantly being flexed side to side. That's why manufacturers often use MLS gaskets, SS flatwashers, and don't torque the manifolds beyond spec.

Sometimes the broken studs come out suprizingly easily by just massaging them out with a pick. Other times you just need to mig weld a little glob of metal onto it so you have something to grab onto.

TIP: Weld in short bursts so the metal builds straight up in one spot. Don't hold the welder on so long that the material drips.