Try mopar brand rust penetrant, from the dealer, it's amazing, it dissolves rust.

Then heat and vise grips. You can also grind a flat groove thru the top with a dremel or cut-off wheel and use a standard screwdriver or drill for some added torque.

Be careful if you use the drill.

 

SNAPPED OFF FLUSH TO HEAD! Grrrr

 

Get a nice sharp center-punch, and poke a dot in as close to the center of the bolt as you can. Use a fairly small drill bit, and drill a pilot hole thru it. Then, step up to a slightly larger bit, and bore the hole again. Go as large as you can, without eating into the threads on the head. then warm it nicely, and try an easyout/broken bolt extractor.

 

Breaking out drill.

 

Hope this deosnt happen to me if i attemp do this myself. Can you take some progress pictures and post them. The solution to the problem.

 

What ever you do, don't snap an easy-out off in that bolt like I did. Ugh, couldn't drill through that at all. Ended up taking the head to the machinist at work to get it out.

 

No... you won't find a drill bit that will cut thru an easy out. At least, not for less than about 30 bucks.... (for ONE bit....) But, you CAN shatter them. Use the center punch, and whack it hard a couple times, and it should blow itself into pieces.

 

How would I attack it? That would call for a ground invasion with plenty of air support.

 

Ended up drilling it out and tapping it with a 5/16th tap. It wasn't easy to tap because of the design of my tap only allowing me a quarter turn before hitting the valve cover, after getting a good tab started, I put the intake manifold back on. Then I was able to use the intake manifold and use it as a guide to do the drill one last time to clean out everything and make sure it was all straight. Ran the tap down through it again and actually got all the way down through the block. Then was able to use an intake manifold bolt, just like it was stock.

 

Awesome! Glad to hear it worked out.

When I did my plenum the top of the rear drivers side bolt snapped off. It was not fun. Luckily, it was loose enough that a small pair of vice grips was enough to get it out.