So far spent about 4 hours trying to replace the passenger-side stock exhaust manifold on brother's '99 6.0.

The dipstick tube won't come out for ****.
All the bolts came out fine, except for the one that has been broken off in the head causing his exhaust leak....and of course it is the farthest one back on #8 cylinder.
Tried to drill it and use an ease-out to get it out...broke drill bit off in the bolt and now I'm fucked.

Anybody got any ideas where to go from here? Pulling the head is not an option.

 

You said it yourself, You are fucked. The only thing i can think of would be to get a really powerful magnet. So long as its far enough away from any electronics. You could try pulling it with an electromagnet. It's easy enough to make if you got copper wire and some batteries.

 

its damn near impossible to drill out an easy out, ive tried and broke 3 bits. theyre pretty hard metal. i think pulling the head will be the only solution,

 

Guess I'm gonna try a dremel with a steel high speed cutter bit and see if I can get all that junk out of way. Should be fun.

 

Did you happen to watch Monster Garage last night? You could always just do what they did to that Miata.

 

thats the same **** i have going right now! let me know if you find some kind of easy solution right now im pull the motor paritally out unmounting it and pulling it up to get a better angle on it and try an easy out hopefully i wont break it off in there.....

 

Time for some some aluminum 317 casting heads shaved .025". Maybe a small custom "torque" cam while you are in there. I'm sure TSP can hook you up.

 

dremel a slot in the bolt/EZ out then try and use a slot to get it out

 

Miata go BOOOOOM
That thing sucked
The screw is screwd R.I.P

 

LOL! Yeah, I caught the end of the show last night right after I gave up on that damn bolt. I was ready to send the truck off to Jesse and let him blow it up.

If the heads have to come off, they are going in the dumpster. Hello LQ9 heads.