Help needed after getting very fustrated trying to get the last remaining stud out from the offside front, I've tried everything I can think of including a stud removal tool, soaking in wd40, smacking lightly with hammer, freezing with shock and unlock, nothing works. All the others came out with no problem, this one however sheared level with the nut leaving the remaining stud sticking out of the engine Sent from my iPhone using Tapatalk
That's an ugly scenario and I feel your pain. Heat is your friend...the only thing you didn't mention was heating the area around the stud with a propane torch, then using a stud removal tool or a largish vice grip. The most likely thing to happen will be the stud will break level with the head. It is still possible to repair it with good sharp drill bits and a heli-coil thread insert the right size and pitch. Begin by grinding the remaining stud level with the aluminimum surface. It's dicy work drilling steal out of aluminum so start with a small hole in the middle of the stud and work your way to successively larger bits until you have the right size for the thread repair. The key to doing this successfully is making sure your pilot holes are in the EXACT center of the stud. If you don't, once the drill bit finds the softer aluminum it'll want to go there and you'll end up with an oblong hole. If you find this is happening, you can use a dremel with an eighth inch carbide bit to recenter your pilot hole or finish grinding out the remnants of the stud. Good luck, take your time and be careful.
If what Dizzy suggested doesn't work for you Magee you might want to try this. This is an easy little trick that my buddy Pez uses to remove broken studs/bolts and it works every single time. Get yourself a nut that will fit on that broken stud. Hold that nut up to the broken stud with a pair of needle-nose pliers and tack weld it onto the stud. Make sure you've got the wrench that will fit on that nut you just welded on close by and ready to go. Work quickly while the stud is still hot from the tack weld and rock it back and forth a few times to break the torque. Then simply just spin the broken portion of the stud out. If you get the stud turning and the nut breaks off the stud at the tack weld,give it a little bit of time to cool off and try again. Good Luck.
Thanks for the advice, couldn't get it out though in the end decided to Weld a threaded rod on the end of the stud, not pretty but did the job! Sent from my iPhone using Tapatalk
