on my 5.3 the back manifold bolt on the driver side has broken off in the head, anyone else had this problem? If so how did you remove it?

 

How about this
https://www.performancetrucks.net/fo...highlight=Weld

 

Really common...Sometimes the head pops off and you can use a vise grip or stud remover to get broken piece out. If it is flush try and weld a nut to it.
GM has different bolts with 13mm heads on them to replace 10mm head bolts. I've seen the larger head bolts breaking too. Just did a 08 truck yesterday that had the front and rear bolts on both sides broke.

 

I am about to do a head swap and have the old style bolts. I would prefer to replace them with something that wont break. Any suggestions? I was looking at the ARP studs but they are $$$ for manifold bolts. Anyone have a parn number for the new style bolts?

Also, I have heard something about drilling the holes on the manifold a bit larger so they wont shear the bolts off when the manifolds expand. Not a lot, just a few thou over. Anyone done this?

 

I've had this happen on another guys truck and wound up having to pull the damn head off to be able to get to it!

 

join the club!

 

Soaked it in Kroil (industrial strength PB Blaster) a couple of times when the engine was cool and let it soak in overnight, then backed it out with Vise Grips. Took a solid hour, 1/8 turn at a time. But I would soak all of the bolts in some sort of penetrating lubricant overnight at least once so they back out more easily.