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2nd Gen Ram Tech1994-2001 Rams: This section is for TECHNICAL discussions only, that involve the 1994 through 2001 Rams. For any non-tech discussions, please direct your attention to the "General discussion/NON-tech" sub sections.
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.
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.
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.
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.
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.
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.