while i was removing my exhaust manifold the top left stud snaped and part of it is still stuck in the head with about 3/4" hanging out and i cant get it out so i was thinking about getting a bolt welded on so that i can remove it

1)will the manifold leak without this stud?
2)how can i remove this stud?

 

Have you tried PB Blaster and channel locks?

 

Yes, Vice Grips work well for this. It happened to me several times on 1G DSM's.

 

mechanic tip from my friend who owns a shop:

hit it with PB Blaster and wait 15 minutes.

heat the exposed stud with a torch to get it good and warm.

get a birthday candle for a cake and wick as much parrifin wax into the joint between the bolt and the head. (this wax will lubricate better than penetrating oil)

clamp vice grips on the bolt while still hot (allows the vice grips to deform the stud more, yielding a better grip)

let the bolt cool and then remove by slightly tightening first then trying to loosen the bolt.

 

im not sure if i would heat a steel stud in an aluminum head might not be the best idea pb blast vice grips rock it tight and loosen till it becomes free i have seen people with these things that dont leak yet it can cause a problem.

 

Factory service manual states that you sould replace those studs everytime the manifold is removed. Might want to do the rest while you're at it. One of my friends had popped one, a couple weeks later, three more popped...

 

yes, eventually that missing bolt will cause problems. warped manifold, exhaust leak, you know, that kinda stuff. and like the guys said, vice grip and rip! good luck.

 

the CTE (coefficient of thermal expansion) of aluminum is much greater than steel. therefore heating the stud will actually cause the hole to get "more loose" b/c the aluminum substrate will grow more than the stud will. I've personally done this several times with no il-effects. I also said to heat it, not make it glow.