Broken Stud for Air Intake Manifold

The studs can come out The stud has threads on both ends sometimes you can heat it up a little bit not enough to be melting things just to get it hot and then a good set of knipex pliers attached to the stud the correct direction for lefty loosey turning and a good oomph that will come undone If that doesn't work you can double nut the threads you can see if that's possible I don't know I don't see where it's broken I guess it's hidden behind that plastic business so I don't know if you've got enough to grab onto or not other than that depending upon what kind of metal removal tool you can get down there a sawzall with a flat blade where you can trim what's left of the stud sticking out flush with the aluminum and then take a center punch punch the center of what was left of the stud and then drill with a small drill bit say an eighth of an inch a little bit less get a pilot hole in the center of the stud using one of the other bolt holes to measure the depth so you don't go through the aluminum block assembly and drill all the way down to that depth You may be able to shoot some k r o i l down the hole you just made in the stud and you may be able to get your extractor in there tap it in nicely and get it to work out a little warmth may help If not then you're drilling all the way until the minor diameter of the threads that's the edge of the threads and then you can run a tap in to chase out the very little bit of material left clogging up to the what would be the major diameter I guess then that'll leave you a clean hole to insert a new stud and or a both whatever makes you happy notice there's both on the intake.

 

Intake manifold info attached. Torque for both the nuts (on studs) and bolts is 21 foot lbf. I see that stud torque is NOT included. Will dig a bit more.

 

You can see how the one that isn't broken ends with a Torx shape; they're made so you can use an external Torx socket to unscrew them and screw them back in. So the broken one is missing that of course, but there seems to be plenty left to clamp some vise-grips onto.

 

Screen capture from last link in my signature (full engine section from repair manual). Torque value for studs is 84 inch lbf:



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