Replacing the stock exhaust manifold with the JDM OEM 4-1. Bolts came out fine, right lock nut no prob, left sheared off flush with the head...

Tried to tap it out with a center punch, nothing. No room to center drill it either. I figure I'll just stick the header on without the left stud and hope it doesn't leak.

Anyone have any suggestions? I wonder how much the dealership would charge to pull the head and correct this......

 

If you pull the head off yourself you can bring it into a machine shop and they can take that stud out for about $20.

 

I have a friend who did the same thing. Its been like that for at least 5 years now with no problems for him.

 

Pull the head, and set it down on a table(or anywhere else ya like). Then the only thing i could think of is to reverse drill it out of the head. You can get some reverse drill bits pretty easy try home depot? Just Punch a starting hole into the center of the stud, and start drilling. KEEP IT STRAIGHT, and jus hold steady and keep drilling. The stud should catch and the drill should turn it out of the head. hmm...im pretty sure you might have enough clearance to do it straight from the engine bay too. If you dont have enough room, pull the fan and radiator, i rather do that than the head

 

If you can get the car to a welding shop they can weld a piece of metal onto the broken stud if enough of it is showing and then maybe work it out with some heat and oil/lube.

 

good idea GSRoadrage. either will work though