If it's not siezed in there, you could drill into it w/ a left hand bit, and then an easy out. Just talked w/ a friend about similar problem, he said you got no idea how many broken ez outs he's pulled out of engines. He says if an ez out would work, you wouldn't have broke the head off loosening it.

Good prevention: Whack it hard w/ punch & 2-3 lb hammer before loosening- this will break the bolt loose from any corrosion/galling before you loosen it.

You could also drill out and rethread w/ heli coil.

I just took the head off a bolt in my suby's thermostat housing, drilled into it, ez out didn't work, and I broke a drill in the hole trying to go next size up. Flange was open on both sides as opposed to a blind thread, so I drilled thru w/ a 3/16 masonry bit, and then a 1/4. Carbide insert on the masonry bit ground thru the drill. Don't work it too hard and check it, if it gets hot enough the braze holding the carbide on the drill will melt, and you are on the the next level of screwed. Obviously, no threads left in the hole, but I just nutted a longer bolt on the exposed far side of the flange. Not pretty, but back on the road.

The cover with the thru hole will act as a guide bushing, and center your drill.

Other suggestions:
Slot the protruding stub w/ cutoff wheel, remove w/ flat screwdriver
File flats on the protruding stub, grab w/ visegrips, wiggle back & forth, use heat & penetrant.

__________________
CC: NSA

All things are burning, know this and be released.

82 Benz 240 D, Kuan Yin
12 Ford Escape 4wd

You're four times

It's hard to

more likely to

concentrate on

have an accident

two things

when you're on

at the same time.

a cell phone.

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