highpsi04

Just slowly drill a small hole into the bolt keeping it cool like sxynerd said. Once you get about 1/8 inch into the bolt use an easy out to get it out. If that doesn't work just drill the bolt all the way out and helicoil the hole. More then likely you cross threadded the bolt so you will have to helicoil it anyway. Aluminum doesn't like being retapped.

jvog

I tried drilling a small hole but without keeping it cool and I failed miserably. I will try using some PB blaster with it next time. Its definately not cross threaded, I just overtightened it like a retard.

Thumper2Kewl

Well the way i would do it, and have done it many times. Cover all the timing components and get a small nut just bigger than the size of the bolt. If you have access to a small mig welder hold the nut centered over the broken bolt with a pair of pliers and weld it to the bolt. Then it should come out real easily. This has worked for me many times.

Hope it helps ya.

cbbass123

i've always used heat to loosen broken bolts stuck to heads. Heat and a reverse drill bit kit.

devongarver

damn, the welding idea is a good one, I never even thought of that.

Sxynerd

If the bolt is in anyway recessed in the head, there's no way to do it that way without instantly melting the aluminum.

jvog

Exactly what I was thinking.

I just tried the drilling while using some PB blaster and failed miserable. Theres like a little dent in the bolt, but its becoming horribly off center and its not actually drilling into it. I just broke 3 drill bits. I guess I need to take it to a machine shop.

01GTDropTop

If the bolt is not recessed and is pertruding, use some PB blaster and get a pair of small vice grips. Grip the little **** and slowly turn the bolt out of there. You did oil the threads before installing, correct??

This is what I did when I broke an intake2head bolt on my brother's truck. Then again, i did another one, but it was recessed. Now that one was a B*TCH! I used some easy outs from Harbor Freight. a #2 was perfect.

Thumper2Kewl

LMAO well theres always a way but it wouldnt be very economical for me to drive to PA to show him how lol,

Anyway if the bolt is recessed a little just simpley make small tach's on the end of the bolt to extend it and let it cool a few minutes after each tach. then weld the nut to it and your good to go.

jvog

the bolt that broke off is a little 8 mm bolt, I just don't see how that leaves much welding room.