I've got four studs, that broke at the manifold, and are stuck in the head. I'll post a picture on my break, but there is about a 1/4 inch of the stud sticking out the head, on all four studs, but they don't have a nut on them to put a socket on anymore, those snapped off. I've got new headers on the way and gaskets already, but I need to get these out first. I don't have a welder and I'm not experienced. I've got a MAP Torch, but even with heat the vice grips and pliers just slide. They're round with no threads on the exposed part of the stud. I'll post a picture here in a little bit.

A couple ideas my friend and some others said, let me know if any make sense or are destined to fail:
1. Heat it up, put vice grips on it, then spray computer duster on the bolt to get it to cool down really fast. Shock the bolt loose.
2. Put the stock manifolds back on with a temporary gasket, drive it to a welder, take the manifolds back off, weld a nut to the studs and take them out that way. Then just put the new headers on there.
3. Say Screw it, and just put the headers on with the broken studs still in there.
4. Get an air hammer and try that out?
5. Get a huge torch from a buddy and have him heat it up until its red hot and continue trying with pliers.
1997 Dodge Ram 1500 5.9L Gas 4x4 single cab short bed

Thanks,
Jake.

 

Clean what is sticking out really well, and as well as you can around them. Spray with chemicals. I like PB Blaster. Let it soak in for a bit. Hit 'em again, and tap on the ends of the studs with a hammer. You don't want to pound on them, just tap. Then put the vice grips on there, and make 'em TIGHT. Work it back and forth, until it breaks loose, then they should come right out.

 

 

That's all I've been doing this last week and it's not budging yet lol

 

You could thread them with a die and double nut them. I like the idea where you go get nuts welded on. I wouldn't even bother with a gasket.

 

Ah I hadn't though of that, not bad, thank you. I'd rather get them out and just replace them with bolts before I get anything welded though.

 

Weld nuts to them, then use the nuts to extract the broken part.

 

This worked for me along with some Knipex pliers - the jaws on Knipex pliers are much harder than Vise Grips and grab studs extremely well.

While you're at it, go ahead and remove those spark plug heat shields - they will end up allowing debris to collect around your spark plugs and can cause similar issues with hard to get out spark plugs. You can remove them by taking Vise Grips pliers and grabbing them and rock back and forth and yank them out.

 

It also looks like there might be enough to get a pipe wrench on. Like Hey You said, you weld nuts on and use them to back the old studs out. The heat from welding helps them come loose.

 

i would be using torches like atomicdog posted. welding a nut on there would almost be a waste. heat that thing up with a torch till it is glowing red and it will just walk right out. most of the time you never get that lucky and have something to grab onto. it is when you have nothing to grab onto that i would suggest the welding route.