On my van, 2003 E150 - 4.2 V6 I snapped one of the lower intake manifold bolts. Wondering what the best way to extract the half still stuck in there is?

Where can I find a replacement? I called a local dealer and they didnt have anything.

 

Have you removed the manifold yet? If you can still grab the bolt stub with a locking pliers, try that first.

To find an exact replacement, take one of the good ones to your local scrap yard to find the same engine, and pull one or more that matches yours.

Failing that, you can take one of your good ones to a good hardware store and find a more generic replacement that matches yours.

 

Drill, heat & easy out.

 

I was going to say torch it, but if it's in the open lifter valley, I would be real careful to not set the oil on fire.

 

Thanks for the suggestions, upon the rest of the intake bolts I discovered I had 3 broken bolts, two of which were at opposing angles, each with about 1/4" left protruding up into lower intake manifold preventing it from being removed. Unbelievable.

After attempting to squeeze my head in there, with a drill, I decided to to try and pry it off (off the broken bolt stubs). My dad ended up helping and the two of us each with a flat bar were able to get it off with minimal scratching to the mating surfaces. I was then able to use vice grips to grab the broken bolt nubs. I used some metal surface sand paper to gently brush off any raised bits where the flat bar scratched or where the bolt nubs dragged. The third bolt I was able to drill into and use an easy out.

The replacement bolts took me some searching but I found the right lengths at a local hardware store.