I have an '91 Firebird, w/ a 305 TBI...and i changed out the raditior, so i was going to change the thremo in it, where the neck on the intake is, there is 2 bolts, well one of them snapped off, just the head of the bolt, and now the stud is sticking out of the manifold...1st i tried heating it up w/ a torch, and used some vice grips, didnt work..then i tried an easy out, drilled it out and everything, and almost broke the easy out and that didnt work....i mean that sucker is stuck, i just was wondering what else can i do? cuz i sure dont wanna go buy me another manifold for one bolt that i can not get out...ne help would save me money and time, thanks alot.

Jim

 

Sounds like a perfect opportunity to ditch the TBI!

Seriously though, did you use any type of rust removing spray on the bolt?

 

Drill a hole through it, and slide something into it to torque it out???

 

I used tons and tons of WD-40, and already drilled a hole in it, and those easy outs are so cheap, when u try to torque it out of there, it almost breaks...

 

Tap on it a little with a hammer, then spray WD-40, tap again lightly, then try the easy out!

 

I meant drill a hole through its horizontal axis, not vertical like an easy out.

 

If you drilled it pretty much down the center, you can through-drill it as suggested, then step up the drill size until you can re-tap the hole. If you have the common 3/8-16 bolts, you'll need to drill up to 5/16" to start the tap. If you have a water outlet/thermostat with the rubber seal instead of the gasket, you may have smaller metric bolts.

 

yea that sounds like a plan, right now i have it soaking...and ill see if i could drill a hole on the side of the bolt, but 1st ill try soaking it some more w/ the WD-40, thanks guys.

 

Man thats got to be a pita.

 

Cut a slot in the top that you can put a huge screwdriver in, and turn the screwdriver with a wrench. Or, use a grinder and file six edges on it, doesn't have to be perfect, get a socket on there and crank it out. I've invented all sorts of ways to remove stuck screws. Matt

 

if you have enough threads showing try and thread two nuts on, then just jam them together and use a wrench to turn the stud out

 

Heat it up with a torch again and quench it with some penetrating oil. This will draw the oil into the threads, and loosen it up a bit.

 

Since the head broke off, I doubt if your going to be able to muscle it out.
Try a true penetrating oil instead of WD-40.
Give the oil time to work. The more time, the better.

 

Vader's suggestion is what you will probably end up doing. you can always go to a 7/16 bolt if your slightly off center, this is common on alluminum manifolds. In my case, once i break the bolt and go through the trouble of drilling and taopping it, i make a stud from a bolt and put a nut on it, it won't happen again this way. If you want to try the penetrating oil idea get some aerokroil and go with the heat idea. Once you get it out, don't forget the antiseize!