Express van removal of broken exhaust stud without removing manifold?

[Hank3band]

While I'm swapping transmissions in my express van, I decided to repair two broken exhaust manifold bolts. It is the rear most bolt on both drivers and passengers side. I got the driver's side exhaust manifold completely off without too much fuss. The passenger side looks a little tighter quarters. Anyone have any ideas to remove the bolt pictured without removing the exhaust manifold?

My right angle drill is too large to hit the broken bolts square with a drill bit to drill it out. Looking for ideas and advice. Thanks in advance.

 

[Jdeere562]

Where are you located in Iowa Hank3band?

 

[Hank3band]

Where are you located in Iowa Hank3band?

Des Moines

 

[Jdeere562]

Sorry, in the Council Bluffs area.

 

[carviewsonic]

I had the same position bolt on a Cadillac 425 drilled out by a mechanic who tack welded the drill bits to an air ratchet. The air ratchet was compact enough to fit in the available space. The drill bits had to be cut to a shorter length as well.

 

[Astro14]

In a similar situation, where my angle drill wouldn’t fit, even with the shortest bit, I used an angle driver attachment like this:

Holders | DEWALT

The DEWALT MAX FIT® Right Angle Attachment features a compact 1-1/2 in. front-to-back design to provide users with accessibility in close-quarter drilling and fastening applications.The metal-gear case design provides durability and 2X longer lilfe* while the addition of a robust magnet...

www.dewalt.com

into which I chucked an impact bit. The whole combo was about half an inch shorter than my right angle drill, which was just enough.

 

[Hank3band]

Two jam nuts tightened against each other and it came right out. I'm surprised it worked but excited it was easy.

 

[clinebarger]

It's going to be difficult to drill the passenger side one straight.

Removing the manifold is likely best.....Then you can try the double nut trick again, But don't be surprised if the bolt breaks off a little below flush. You got lucky getting the drivers side bolt out in one piece.

Buy a set of ARP bolts part# 134-1102.