When a screw is rusted in place, it’s a good idea to douse it liberally with lubricating fluid and wait 10 or 20 minutes before extracting it. Get the monokote heat gun and heat it for a few minutes until it is good and hot. If the allen key slips get an “Easy Out” screw extractor to fit, then heat with the soldering iron and extract. Using a small tip visegrip to lock to the head of your screw is the best way if the soldering Iron wont work. The SS will hold up to using a impact. The circular ones will not hold their shape when you bend them and will skew under pressure. The fact that its a slotted head probaly means its soft so will drill a lot easyer than the 12 grade hex ones will. Something else to keep in mind if you can get a good punch on it is the jarring from hitting it with a hammer will often help as well, I wouldnt be afraid to heat it, if you do and it doesnt work, and you later have to drill it out, then just weld a bit of 7018 rod right on it, this will take care of any hardening that may have happened while heating, you can drill threw the weld like butter, and it will mess up what ever surface hardening occured from the torch.
If their is a bit of the stud sticking out, try welding a nut on, if it’s broken of flush, and it is not a blind hole try torching it out, last, center punch and drill ( if the bolt is broken of below the level of the casting, use a layout punch) then use an extractor. If it indeed it is a bolt still drill and punch out. Just drill out to lets say 5/16″, go to the parts store a buy a pack of 5/16″ “christmas tree” fasteners. Only buy the type that has a grooved point that bites-into the hole drilled into a stripped screw. 1. Drill a small hole in the middle of the screw head. Squeeze the trigger to start the drill at a very slow speed, and allow the extractor and drill to pull the screw out of the object. One of the least expensive extractors seats a collar over the stripped screw then uses an extractor bit to pull the screw out. Not only does the Gutster pull nails with monstrous leverage using a multi-nail puller conveniently built into the back of the head—but it pulls everything else apart as well. Using stainless rods. Then you can back it out.
I have been using screw extractor sets for many years after first learning about them during my apprenticeship as a mechanical technician in the Royal Air Force, where I served as a technician on aircraft for 7.5 years. First I have to remove the tail rotor mechanism on the gearbox. I am trying to fix the tail gearbox of my LMH Corona. By now I’d learned to always heat the bolts before trying anything, so I got out the torch and kept the flame in place for a good 60 seconds. Idea uless your srew is jammed in there really good. There are two bits that come in a drill bit extractor set. Insert the bit into the hole you just drilled and begin drilling to the left. Always wear safety glasses when drilling, especially when drilling into metal. If your car lives wear they salt the roads, it just exasperates the problem.
Trying to extract the broken stud wile laying on your back under the car is going to cause no end of heart burn. Broken stud. Then weld a nut on to the washer. Brass nuts cost a few cents more (this is wy the manufacture dosnt use them) but are cheaper than fighting a broken stud. I recommend removing all 6 studs (assuming you have 2 manifolds) replace them with new studs and plenty of antiseise and brass nuts. If you’re a wine drinker, you should realize there are plenty of ways to get corks out of the bottle. I feel dumb for asking but there are no dumb questions, right? Hand driving the tool allows the operator to feel if the broken screw is correctly engaged and to make the necessary corrections as required. As such, with this set in your toolbox, you will rarely encounter a situation when you don’t have the right tool to remove a damaged piece of hardware. Wondering how to remove stripped screws from wood if all you have is screwdrivers?
Old paint is like glue holding those screws in place. X Research source – If it doesn’t work, try tapping the extractor in harder, or apply a lubricant like Liquid Wrench to the screw. On the other hand, if this does not work, you may be worse off than when you started. Once you’ve started the hole, change the bit to the size of the embedded screw, and enlarge the hole to the size you need. I have also used a left-hand drill bit to drill the screw out; works well but you have to order the LH drills since nobody stocks them. I highly recommend antieceise on exast and coolant system bolts, as well as weal lug nuts ( use a tork wrench, saves heart burn on the side of the road). I use 2 types of grease, one for general use like this S10 grease and another one that’s a bit thicker if I want the helicoids to be stiffer. Do not use a heat gun cuz you may melt somthing you don’t want melted. The problem is two of the allen screws don’t want to move and the allen key that I use just slips.