This all started here: https://www.cherokeeforum.com/f2/par...5/#post3716585

But it might have bricked my jeep for now.

Basically I went to replace the exhaust manifold and both of the studs broke off below the surface on the block.

I got the front one out by destroying a screw extractor kit. They should say they’re only good for one job.

After getting another kit for the rear one I made the first centered hole.



Then I thought I'd try those speed out bits to make the next size up and it made the hole off center.



So I went back to the harbor freight kit. But I had to cut it off to fit it in there.



That drilled it out enough to get the extractor in there, the#3, that worked on the front one.

It turned about a half turn! But then the cheap harbor freight extractor stripped a little and popped out.
Hard to hammer it in there in tight quarters.

So this is when it all went to hell. I thought since it’s loose why not try the extractor side of those horrible little “speed out” pieces of junk.

I put it in the drill and it immediately twisted off like butter.





I’m dreading tucking myself into the engine compartment to tap on that broken bit to see if I can dislodge it. I’m pretty sure everything I have to tap on it, including this new set of chisels and punches, is a softer metal than these studs and that broken bit.

 

Hate to say it but your not getting that broken bit out..you can get a rebuilt head for a couple hundred bucks and you've done most of the work already

 

I have seen this issue several times, the best way I have found to remove this is to get a flat washer to cover head for a bit of protection, then get a decent size nut and mig weld the nut to the stud in the head. The weld shrinks the stud and hopefully will allow extraction, however this one will be tough to do as it is broken off inside. The other option is keep drilling and maybe if required go for a bigger stud.

 

Well, a good machine shop can get that out. Of course, you'll need to remove the head. Once out, check the rest of it. If it needs other work (decking, valve job, etc.) you might was well get a reman.

 

I would drill it out completely, tap the hole the next size up, make the manifold hole bigger, and bolt her down.

But that is absolutely not the right way to fix it.

 

I have advised all necessary actions on the other thread, and in which order they should undertaken

starting a new thread wont make the job any easier

Some of the advice has been repeated here

If you take the head off, a machine shop will do all needed work (which would include head job, for which all studs must be removed, machine shop hour$)..but an anecdote of caution

I once took a very rare 80yr old truck exhaust manifold to a machine shop to get out a busted easy out

They politely told me to **** off

I went home, took a small sharp ***** punch and small hammer and busted that **** right out of there

As I mentioned, very hard things are brittle

That drill bit will probably not be as brittle as an easy out, but should shatter

A plain old arc welder can be ..versatile, and can certainly be used for induction heating or spark erosion

I am not a pro engineer or mechanic, but have 50yrs on old machinery, my success rate on getting these problems solved has gone up vastly over the years

 

there is a ~90% chance this will work

just buy a cheap Invertor Arc welder, they weigh just a few pounds, cheap as dirt

select a medium thick rod, cut to ~3"

place end firmly on broken drill and turn welder switch on

The rod and drill bit will begin to glow redhot,

hold it until they fuse together, switch off welder

have multigrips handy and twist or yank out broken bit using the welding rod, with luck, the stud may come to

be thoughtful, things can go wrong

 

I'd be tempted to use a small dremel cutoff wheel and cut a deep slot and then use a screwdriver. JB weld or silicon up the slot in the manifold afterwards.

 

I called around to several machine shops and got told that nobody would touch it once a bit is broken off in there. One said maybe I could take it to ABQ.

I ended up ordering a new cylinder head. Or, I thought I had. I asked the wife to handle it.

Now, since I thought a new one was on the way I went all cave man on it with a hammer and metal punch and shattered that stuck cobalt extractor bit head!!!

Just needed to not worry about breaking the head and bam. Victory.



Screw those extractor bits! This is what got it out. Torx star bit


Oh and the craziest part? The wife called saying that the new head couldn’t arrive before August, 3-4 months from now!

But, the illusion of having a mew head on the way got it done. Mind blown.

 

Excellent work and determination...I would have bet against you..glad I was wrong

 

Yeah I had broken stud in the pool too.

 

Atta boy nice work

 

I was always hopeful the OP could do it

I hope my remarks, which can come across as rude & condescending merely served to hopefully inform, and possibly motivate the OP into enough annoyance to get in there

Congratulations, and now you can get the thing back on the road !

Good idea on the Torx bit, I have indeed used Torx (other bits) bits in the same way on mangled screws

A Torx bit is very similar to "straight fluted" Easy Outs. The tapered ones expand the shell wall, and I basically avoid using them

For exhaust bolts, others may disagree, but heat is essential, my mate owns a exhaust shop, oxy heat is standard, butane will do (just) for the homie

 

Thanks! I often seem to come across as a jerk in forums too. Though I try not to. So I get it. And I don’t mind. I try to see past it anyway and take the helpful parts, leave the rest. Besides I know us fellow Jeepers are awesome, even if a bit crusty sometimes. It’s just the nature of it all I guess.

Thanks everyone for your input and maybe even for telling me I couldn’t do it. That made me more determined. Ha