I got my 6.0 today from LKQ, and as normal with these LS engines, there are 2 exhaust manifold bolts broke off in the heads. On the first one i tried drilling into it and using an EZ out and it didnt work. I drilled further and the holes is going crooked so i stopped. I have not tried the other one yet, it is broke off flush with the head also.. Whats the best way to get these out without drilling into a water jacket? Kinda hard to drill perfectly straight..

 

If they are fairly close to surface then tack weld a nut to the broken bolt and then screw it out.

 

Put a nut over it and weld the bolt to the inside of the nut. Then remove with a socket

 

Yea weld a nut onto it. The weld want stick to the aluminum head. Also the heat from the weld will help the bolt come right out. Done this numerous times to junk yard heads! Works awesome!

 

will give that a try on the other side. The side i have drilled is too deep to weld a nut to, its about 3/4 inch deep..

 

A torch (not a propane torch) and wax will loosen them up. Heat up the broken bolt only and press wax onto the bolt. The wax will penetrate enough to help loosen the broken bolt to turn it out. But before I go that route though I swear by PB Blaster. If you already have a hole started but its not straight enough to continue drilling you can always straighten the hole with a die grinder and continue from there.

 

welded a nut to it and backed it out. worked awesome!

 

hope i get lucky and none of mine break, doing header install next week.

 

hope i get lucky and none of mine break, doing header install next week.