Oh the Joys of header installation. Passenger side, everything came out fine, broke 1 stud pretty close to the head. Drivers side is a different story. Top rear and bottom 2 rear can't break, and can't turn. The rains came so I'm in the house pondering now LOL

Oh did I mention that the 3 nuts at the converter flange, are rusted little ***** of ohhhhmygawdhowamigonnagetemoff LOL

Just venting, I've read a ton of threads here on header installs and basically wanted to see how it went before I started buying extractors and such.

 

I think several members have gone through this with better luck by welding and extracting. I will say though use some PB blaster, kroil or some penetrating oil prior to removing so they can soak. I would also apply some heat with a propane torch to the area to help loosen things.

 

I'm trying to bum a 110v mig as we speak. As of right now, i still have 3 to either break or cut off on the driver's side to get the manifold out.

 

I used an entire can of PB blaster, per side. Luckily got all but 1 on each side out. PB BLaster seems to work well. And, I have used in the past with good success. If you already have the manifolds out, and studs are broken off flush, not much help I can give you...............but, if you still have some studs left, soak the S*&T out of them with PB Blaster and let it sit for a bit before you try to back them out. That's what worked for me.

 

I have one broken flush with the head on the passenger side, Rear most top. The driver's side manifold is still on the truck, One stud, rear most top is all that is left. The nut is rounded till there is no more. I got rained out this evening, I'll try and tack a nut to it tomorrow or wednesday. I'll feel very accomplished if I can just get all the old crap off LOL

 

Drill them out.
I had a pile broken in the head and I welded to them and they bust off. Drilling them out with a reverse twist worked well.

 

Drivers side manifold finally off. Total broken stud count is 4, 3 on drivers side all protruding, 1 on passenger's side flush. Tried welding on the drivers side to no avail. Maybe I'm doing it wrong but weld would repeatedly break and stud would not budge. Tomorrow I'm hunting for left handed bits on lunch. Looks like drilling is where I'll be.

 

Yup, Thats what I did.
Once you start drilling the vibration of the drill loosens them up quickly.
I bought an air powered right angle drill to make this easier.