Advice on removing sheared off bolt from intake manifold

[9371152233]

Looking for advice on best method to remove a sheared off M6x1 fastener that used to hold airbox onto intake manifold. Photo attached. 1 of 4 stubborn fasteners decided to shear off while being removed. It did loosen several turns prior to breaking. Options I am debating between:

1. Grinding top of bolt to have 2 flat edges and using an adjustable wrench to loosen. Worried that cross section of the bolt will be too small and shear off again
2. Welding a nut on and loosening. This would come with its own challenges since I would have to get creative with a ground clamp. Also concerned that the heat from welding might melt the plastic that the nut is pressed into.

Need a vote/advice!

 

[The Cobbler]

why not grip it with vice grips ?

 

[9371152233]

why not grip it with vice grips ?

That’s another option, I just imagined that would be the first to slip and didn’t want to damage the threads if I go another path. I think the torque may be too much.

 

[danielbuck]

I've never worked on plastic intake manifolds before, but what I would do is put some oil around the base, and then gently tap on the top of the broken bolt with a brass hammer. not heavy hits, but lots of light hits. attach some vise grips to it, then try to wiggle the vise grips back and forth while rapidly tapping the top of the bolt. If that didn't work, then I'd resort to heat. thread a nut down the threads (or use a slightly larger nut if the threads are boogered), weld the nut to the bolt and then wiggle back and forth again (also while tapping with a hammer). I'd just be leery of using heat from the get go, being plastic

for the vise grips, make sure they aren't old ones where the teeth are all rounded off. and get it good and tight. don't worry about stripping the threads.

 

[Wrench97]

Do not use heat on that the insert will pull right out.
Good/new pair of small vise grips try to tighten it first and use plenty of lube, most likely the insert is going to come out or start spinning if too much force needs to be used.
Drill and tap as a last resort I've had them come loose in the plastic while trying to tap..............................

 

[Shiftless]

All of the above
Plus, use PENETRATING oil and not just any old oil you have around. Kroil is excellent but hard to find. I use Blaster or SeaFoam too.

 

[Wamsutta]

From my experience, Cobra pliers work better than vise grips. Just make sure you use them in such a way that the lower jaw always moves upward with the rotation. "Keep your chin up" is a good way of remembering that.

 

[sqznby]

With that much shank sticking out, I could pull it out from here
A little lube and a nice set of vise grips would remove that no problem.

 

[RPH]

Small pipe wrench would beat vise gripes and channel locks. Oil, and light tapping on wrench going both ways.

 

[APEowner]

Is that a bolt or a stud? It looks like the other fastener is a stud and if this is one as well then you're not going to twist it out. Also, at the risk of being called a hack; how critical is that fastener, can you get away with just leaving it as is?

 

[Certified Drunk]

I think it's a stud.
You too much force, the plastic intake will break.
Use of heat will pull the whole insert out.
Any other fasteners hold the air box in, your best option might be to leave it alone.

 

[theoldwizard1]

If you are going to try penetrating oil, just remember, THESE TAKE TIME TO REALLY WORK !

Squirt it. Wait at least 4 hours. Repeat. I would not touch it until 4 or 5 application. Double nut is your only chance. Look up Shake and Break. Designed for screws, but just us a 1/4" hex to 3/8" square drive adapter and a socket/

 

[BrandonV]

Soak with oil. Order Vampliers. Soak until Vampliers arrive.

 

[Bigblue&Goldie]

Is that a bolt or a stud? It looks like the other fastener is a stud and if this is one as well then you're not going to twist it out. Also, at the risk of being called a hack; how critical is that fastener, can you get away with just leaving it as is?

Those were my exact thoughts.

 

[Wrench97]

Is that a bolt or a stud? It looks like the other fastener is a stud and if this is one as well then you're not going to twist it out. Also, at the risk of being called a hack; how critical is that fastener, can you get away with just leaving it as is?

It's a bolt the other on in the picture is also a bolt with a stud on top of it, common Ford thing......................

 

[mrbill55]

Looking for advice on best method to remove a sheared off M6x1 fastener that used to hold airbox onto intake manifold. Photo attached. 1 of 4 stubborn fasteners decided to shear off while being removed. It did loosen several turns prior to breaking. Options I am debating between:

1. Grinding top of bolt to have 2 flat edges and using an adjustable wrench to loosen. Worried that cross section of the bolt will be too small and shear off again
2. Welding a nut on and loosening. This would come with its own challenges since I would have to get creative with a ground clamp. Also concerned that the heat from welding might melt the plastic that the nut is pressed into.

Need a vote/advice!

KD Tools Studs Camshaft Style Stud Remover 1/4" to 3/4"​

 

[Bad Eye Bill]

Can you thread a nut onto it? If so, try double nutting it. Run one nut all the way down then run another nut down to it then using two wrenches lock the two nuts together then use wrench on the bottom nut to turn out the stud.

 

[MOS3522]

I keep a set of Engineer pliers for that kind of mess - the jaws have holders for stuck bolts. They are amazing.

https://www.amazon.com/gp/product/B07677TBQ6/?tag=atomicindus08-20