Ok guys, I need advice on what to do now

Went out to change the plugs on my 2013 5.0 (50k miles) & while removing the very 1st 8mm bolt, which holds the Coil in, SNAP.... I sprayed all of them with PB-Blaster, tapped w/a small hammer (to shock bolt) & since that had to be a fluke, I attempted to remove a 2nd one, SNAP

There is nearly 1/4 inch of the broken stud exposed (after pulling coil out) so I attempt to remove it with vise-grips (did not work) then I call local Auto Parts Stores to look for a extractor of some kind...Nothing that small

I need some kind of extractor to fit the appx 1/8 inch diameter stud or a great idea.
I can't be the 1st person who's encountered this, suggestions

 

Very surprised nobody has responded to this Thread

Either people aren't reading/responding to "help" Threads in the Gas'r community OR there aren't as many issues with Gas engines, as we had in our Diesel community & so nobody really knew what to do.

I am going to hope its the later & post how I finally ended up fixing it, so the next guy this happens to, has a possible solution.

After a few days spraying PB Blaster on all the Bolt's, I was hoping the remaining 6 could be removed without breaking & the 2 I broke could be extracted by vise-grips.... Well it didn't exactly happen that way

I was able to extract 1 of the broken stud's with vise-grips, but not the other & I broke another of the remaining 6 off, which I couldn't get out either

So in a nutshell, I was able to remove 5 without breaking, extract 1 with vise-grips & the other 2, I broke out the welder.....lol

* See next 3 post's for my solution

 

First, I tried to weld a nut to the broken stud's, in order to get a good bite to turn them out & I figured the heat would help to remove.

I did that by placing a pair of needle-nose vise-grips on the nut I placed over the stud, then attached the ground clamp to vise-grips. A real quick weld from my wire feed welder & I thought I was smart, until the entire stud & vise-grips just fell out of the stupid plastic valve cover

 

That actually turned out to be a good thing & I removed the other broken stud the same way. What I did with the hole was screw a brass furniture type insert in there (picked up at Lowes) after heating it real quick w/a small torch (to aid in cutting threads). The insert uses a 1/4x20 thread instead of the metric 5mm OE uses, so I had to buy 2 1/4x20 bolt's of the same length w/washer'd heads also.

* Pic shows the insert p/n & the insert installed in valve-cover.

 

Lastly, a pic showing the brass insert I used (un-installed) so u have a visual & the completed repair.

In this pic the coil on left is still held in w/OE 5mm & the coil on the right, is held in w/my brass insert using a 1/4x20.
IMO, the difference is barely noticeable & I didn't have to remove the valve-cover g

 

good thinking. If not you could try using a reverse drill bit on the stud, as it is drilling the stud they loosen up at times and back out. But usually that's for flush broken studs on metal bases. Plastic may just split if too much torque applied.

 

Way to think on your feet sir, thanks for posting.

Here's a must have for any tool box: Extractor Sets - Screw & Bolt Extractors - Tools - IRWIN TOOLS

 

Smart man!

 

If it might help I find if you can grind a flat on the side (D Shape the dia.) it helps the vise grips to grab and not spin on the dia of bolt.

 

Anti-seize is your friend!

 

Great thinking on that fix, looked like things were only getting worse and then it all turned out perfectly in the end. Glad I didn't encounter this issue when I replaced my plugs a few months ago. I did really struggle to get a few of the plug boots off though.