How the hell do i get broken Exhaust manifold studs out

[K_Nfilters]

I have 2 broken studs on the passenger side
how do i get em out

Rob

[K_Nfilters]

on a 98 5.4L f150

[ModMech]

If they are broken off flush, you remove the head.

[desertmike1]

Three questions:

#1 Do you have any machining or mechanical training,
This will change the scope of my answer.

#2 Is the stud broke flush or protruding.

#3 How much room is there to work between the exhaust manifold and
inner fender wall.

Removing a broken stud is not difficult, but requires a great deal of patients and carefull work.

-Mike

[K_Nfilters]

1)I am a machinist

2)im not sure if it is flush with the head

3)There is hardly any room because of the frame and susupension

[ModMech]

I'm very glad you have some mechanical backround. These studs are a royal PITA when they break off. You have a high grade steel stud snapped off in an Al casting. *IF* some of the stud is protruding, you can heat the HE$$ outta it, and usually get them out without damaging the head. You rarely have any luck drilling them out because they are hardened by heat, and if your drill slips.... well it's an Al head, you get the picture.

[desertmike1]

Do you have room to get an angle head in there? if so buy a new stud for your depth measurement, and machine a hard drill bushing to tolerances that both match the exhaust bolt hole and a carbide drill bit that can be used for a pilot.

This procedure works very well, I drilled out a broken inconell stud once on the side of a Pratt&Whitney jet engine at the Burner Can where temps reach well over a thousand deg.
You just need room to work!

-Mike