So you broke off one of your exhaust studs flush with the head - what now
Here are a couple of tricks I learned trying to remove three exhaust studs that snapped off flush with the head without removing the heads from the engine. Turns out that the stud Ford uses has a shoulder that damages the first 1/8 to 3/16" of the threads. It is this damaged area that prevents you from extracting the stud.
Extra tools for the job - an air powered right angle drill, you guessed it an air compressor, assorted small drill bits, a jobbers length 3/8" drill bit, and a #3 easy out. First remove the inner fender well cover. Next with the exhaust manifold removed drill a progressively larger pilot hole in the broken stud. Be very careful to drill with light pressure, if you snap the drill bit off in the stud you are in a world of hurt. Once you have reached the proper size for your #3 easy out, you can stop. During this process it is quite likely that the stud has actually been driven further into the head, this is fine. Now take the jobbers length 3/8" drill bit and use it to remove the first 1/8 to 3/16" of the threads in the head, not on the broken stud. Once you have removed this area, install the easy out and walk the stud out. All three came out like butter after I removed the damaged area in the head. Hope this helps someone out there.
Last edited by KTrostel; 08-15-2011 at 04:39 PM.