98 F 150 4.2.
Went to change the thermostat upon putting it back together the bolt snapped off. my error! Now I have tried to heat it and use vise grips no good. Tried to use a hack saw to put a slit in to use a screw driver. No good either. any Ideal before I tear in to intake, I want that to be my last option.

 

If you have room to get a drill in there try to drill it with a LH drill bit.

 

Also if there's enough stud sticking out you can use a stud extractor

 

It might be tight to get a drill there but will try.

 

I was looking at your picture wrong. You can get that with a stud extractor socket. Autozone or Advance Auto has them made by Irwin. It should be no problem

 

LH drill did not work. Going to Auto Zone,

 

Should work, or before you mess up the threads any worse you could run a die down the stud to clean up the threads, then put two nuts on the stud and tighten them against each other. Then use a wrench on the lower nut to back out the stud.

If that doesn't work try the extractor, and if that doesn't work slip a big nut onto the stud and weld it to the end of the stud. Splash cool water on it, wait until it's completely cool, then crank the stud out with a socket.

 

My old Ranger had the same thing happen. I center punched both bolts very carefully to make sure I was as close to the center of the bolt as possible. Then I drilled all the way through the bolts with small drill bit, a 3/16" I think. Then I drilled and retapped the holes to use 5/16 bolts.

 

They're not cheap, but I've had great luck with Alden Broken Bolt Extractors. They're a lot more high-tech and fragile than old-school easy-outs, but they do work better.

 

Yup go with the stud extractor first

 

If you have access to a welder try to slip on a nut, Weld then try removing

 

Heres what i used to remove exhaust manifold studs. They work awsome. If the 5/16 is to big Irwin makes smaller sizes part # 394100

 

Actually this is what you need. This style of stud extractor is certified bad ***. Been using them for years to pull 4.6/5.4 exhaust manifold studs out of heads. They have a cam lock inside. They have so much grip that i have actually twisted the studs off inside the head when they were stuck to that point.

http://c.shld.net/rpx/i/s/pi/mp/1363...587835bff1904b