I just purchased a 99 Durango 4X4, 5.9, and was replacing the plenum gasket. Everything was going good except the right front intake manifold bolt sheared off at the bolt head. I got everything off, and am ready to put it back together, except the bolt shaft is still sticking out about 1 1/2 inches. It is rusted into the threads and will not budge. I have been soaking it in penetrating oil for 2 days, with no luck. I have been trying to turn itwith some vise-grips, but it will not move. It goes into the motor at a 45° angle, so drilling it out might be a PITA. Any suggestions?
Thanks!
Tony

 

Howdy, broken bolts can be quite a pain... Good thing is there is still some sticking out. Before i go into that, did you by chance snap a photo of this? also whats the miles on the ticker. With a bolt issue as that, i'd start off as you did, soaking and soaking, when to no avail, you then can weld a nut to the protuding bolt (giving you the ability to use a wrench/socket). then heat up the area and try to remove. You always want to use extractors as a last call

 

i second that thought about welding a nut on the stud... i have had to do this many many times with a 100% sucess rate..

 

Lucky you, so far my rates maybe around 97%... Tooooo many bolts... Just dont let your freinds know you know anything about anything you dont want to do for them

* Example (89 chevy pu manifolds. "Freind helps freind scenerio") Headers (lotsa space in the engine bay meant something) 8 broken studs... cheap freind so no new heads as suggested to save hair from being pulled out....2 solid weekend days, dusk till dawn, three bolts that snapped twice, two easy, and the rest i dont want to remember.