[DML] Re: Broken Exhaust Manifold Stud

["Sean" <sweitzel@xxxxxxxxxx>]

I JUST went through this with *three* broken studs. Granted, I already
had the engine out of the car, but the concept I used on all three was
the same and I was able to extract all three broken studs perfectly
without having to drill/tap new holes.

Assuming your broken stud is in a position where you CAN get a power
drill at the correct angle, go to sears and buy this tool:
http://tinyurl.com/q5jut

It's a reverse thread drill and extractor. What you want to do is
spray pb blaster on the stud and let it soak for a day or so. When
you're ready to take out the stud, put a center punch on it and whach
the punch with a hammer. This will help loosen the rust bond and also
give you a point for the bit to start in the center without walking
all over the surface of the stud. Get yourself some cutting tool oil
and apply some to the stud and your bit. 

Chuck the smallest extractor into your drill chuck and turn the outer
collet on the tool up the threads so it bumps up against the chuck.
This should leave about a half inch of the bit part exposed. 

Start drilling at a moderate speed. You must use a drill that runs in
reverse - counter clockwise. Drill carefully and straight into the
stud. Stop a few times and apply cutting tool oil. Drill a perfectly
centered hole into the stud about a quarter inch deep. Stop
periodically to put more cutting tool oil and clear out chips. 

When your hole is drilled and the chips cleared, turn the outer coller
down about 8 turns so just the cutting bit and a few threads are
exposed. With the drill still in reverse, bring the drill up to a high
speed, and with the bit lined up with the hole you drilled plunge the
spinning drill into the hole in a smooth motion. In an instant, the
outer collet threads will bite into the stud and it will just back
itself right out!



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