how to get brokein exhaust stud out of cylinder head

[72charger440]

when i was replacing the studs on my engine one of the old studs broke off and is now flush with the hole on the head anybody have any ideas on how 2 het it out?

[b5blue]

You will need to get an E-Z out tap and drill a hole in the middle of the stud to use it. I hope its off the car  .

[Runner]

and if the ez out doesnt work  its helicoil time

[mikepmcs]

Is any of it sticking out or is it completely flush.  If you can get to it weld another bolt to the broken stud and wrench it out.  The heat that the weld produced should make it come out easier as well.

[terrible one]

A few days prior to using the EZ out I would soak it religiously with PB Blaster to ease it coming out when the time comes. You already know it was stubborn!

[c00nhunterjoe]

start the car and get it good and hot, it will make the stud come out easier

[70 500]

yeah get a reverse thread drill bit if nothing is sticking out still, otherwise drill and tap

[72charger440]

cool thanks for all the advice

[TylerCharger69]

I,d like to add...due to trial and error, before drilling and tapping, use a center punch and make a good divot on the center of that stud. Otherwise you may accidentally drill away the threads surrounding the studs in the head itself. Then it would be heli-coil time!!!

[Charger_Fan]

Is any of it sticking out or is it completely flush.  If you can get to it weld another bolt to the broken stud and wrench it out.  The heat that the weld produced should make it come out easier as well.

I had good luck with this once, worked great! I had to re-weld the bolt on a couple times, but in the end, the old one came out & I didn't have to drill & tap anything.

[bull]

Is any of it sticking out or is it completely flush.  If you can get to it weld another bolt to the broken stud and wrench it out.  The heat that the weld produced should make it come out easier as well.

I had good luck with this once, worked great! I had to re-weld the bolt on a couple times, but in the end, the old one came out & I didn't have to drill & tap anything.

I'd say the main reason that worked is because you heated the area and it expanded the metal around the stud enough to loosen it. Which brings me to my suggestion. As mentioned before, use a center punch first to make a dent at center of the stud so the drill bit doesn't wander, then start heating the base material around the stud and begin drilling it with a counterclockwise drill bit. If that doesn't work right away I'd switch to a bolt/stud extractor once the hole is deep enough to give the extractor some grip. The metal around the stud is less dense than the stud itself so it will heat up and expand faster.