What is the best way to remove broken bolts and studs from the heads?

I am removing the exhaust manifolds and some of the bolts and studs are feeling “funny” already.

I have a ’76 ford F100, 360 2 barrel, 4 speed trans, 2 wheel drive and I will be installing headers when I get the old manifolds off.

How about a 90 degree drill? What kind of bits and easy outs are best? Buy a bunch? I know they break also, or should I drill them all the way out and use heli-coils? I don’t have a torch or easy access to one, I would end up removing the heads to do that, something I would rather not do right now.

 

try spraying them with liquid wrnech several nights in a row before your project, or at least one...what about easy outs?<-- DOH! didnt read carefully...

 

Heat. Carefully applied.

I would start with a small gas-welding tip and a sharp small chisel if they broke flush or below the head surface. Heat THE STUD, let it cool several seconds, and then try and back it out using the small sharp chisel and a baby hammer.

. . if it didn't break off flush and you can get a good pliar grip on it the same heating technique will *most likely* get them out in a jiffy.

Stop right there and soak them in penetrating oil! *Try* to work them back in a little while wet with the penetrant. After several minutes (about a bathroom break's worth) back them out ~just~ until they tighten up again and wet them again. The run them back in a little, and go take out the garbage, you lazy bum.

When you come back you should notice the bolts backing out a little further each time you turn them back to wet them again.

The moral of the story: "Patience = Cash Saved" (and knuckles too)

Far out! Do me a favor; stay out of my neighborhood during nap time - ok?

It sounds like waaaay to dang much work to me. Go rent an acetelene torch for the weekend (most any contractor rental place) it's been a while since I did it, but it was cheaper than R&Ring the heads. . . . a lot less work too.

You might also consider a set of reverse (left handed) drill bits come to think of it. If you ~have to~ drill them out, you might as well see if the process it's self will extract them.
HTH.