Removing broken Stainless Steel Exhaust Manifold Studs - 4.6!

[sharonis3]

Any tricks to removing a broken Ford OEM SS studs... got 7 studs out fine but one broke just below the head surface.....

Can I drill out ? or is this a problem ?

Can I weld a nut over the stud location or will the stainless stud not take the weld?

 

[Rick]

I have had good luck with this style extractor:

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Use PB Blaster before attempting to remove it.

 

[sharonis3]

I have had good luck with this style extractor:

Amazon.com: OEM TOOLS 24373 Extractor and Drill Bit Combo Pack (10 Piece Spiral) | Take The Hassle Out of Removing Broken Bolts w/These Extractor Drill Bits | for Metal Bolts Used in Auto Repair & Construction: Automotive

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Use PB Blaster before attempting to remove it.

Will try.....Have you used on the Ford Stainless studs....? Will they bite into the stainless - like they do on regular carbon steel studs......?????

Told a shop replace the manifold and gave them Ford Stainless studs to use..... (with new manifold and stainless studs - so I would be done with this forever).......they thought they did me a favour by reusing the old manifold, that looked good to them.....my view is never reuse a 4.6 manifold that has been leaking, as it is warped.....
Sure enough it started leaking again a couple years later....7 came out easy.... but was broken from overtorque.

 

[94Eddie]

If I ever have to deal with removing the exhaust manifolds on my Mountaineer I will have them (originals or new ones) planed before being reinstalled. This takes any warping out of play. Or see if I can use a set of shorty headers.

 

[sharonis3]

By overtorque - mean it was broken

Will try.....Have you used on the Ford Stainless studs....? Will they bite into the stainless - like they do on regular carbon steel studs......?????

Told a shop replace the manifold and gave them Ford Stainless studs to use..... (with new manifold and stainless studs - so I would be done with this forever).......they thought they did me a favour by reusing the old manifold, that looked good to them.....my view is never reuse a 4.6 manifold that has been leaking, as it is warped.....
Sure enough it started leaking again a couple years later....7 came out easy.... but was broken from overtorque.

i

 

[sharonis3]

Got it out with a #2 size of the very short style extractor.... worked pretty good... it was stuck pretty hard and it fought all the way out.....

One thing I found with the stainless studs - if the extractor slipped - had to red till slightly before the extractor would bite again

these are much better than the very long “old style” extractors-those long ones would snap and leave you stuck with undrillable mess.....

 

[sharonis3]

Got it out with a #2 size of the very short style extractor.... worked pretty good... it was stuck pretty hard and it fought all the way out.....

One thing I found with the stainless studs - if the extractor slipped - had to red till slightly before the extractor would bite again

these are much better than the very long “old style” extractors-those long ones would snap and leave you stuck with undrillable mess.....

Oops spelling - meant if extractor slipped - had to do a light redrill before the extractor would bite again.....also heat the aluminum around the broken stud with a propane torch.....

 

[massacre]

Stainless steel bolts don’t rust
but they are not stronger than regular steel bolts in my experience.
stainless also galls easier but nickel based antisieze can help with that.
i would try heat, as stainless is not a good conductor of heat