Removing a broken bolt from exhaust manifold mounting

[campervankatie]

When trying to take off the exhaust off from the manifold one bolt snapped off half way. Now the the exhaust has been removed there is enough of the thread exposed to get a grip wrench on it - but it is not moving. I have tried giving it some heat off a gas torch and WD40. I have wrapped a wrag soaked in WD40 over it to make penetration better.
Any tips for getting out this son of a bolt would be good. Also if I do snap off this last bit, is drilling it out and heli coiling it out staright forward?
Lastly will I be ok driving the van down the ramps without the exhaust or will my van blow up?
It is a 1.9 diesel.
Thanks for any help

[campervankatie]

Sorry for my lack of stud knowledge.

[VWCamperfan]

Personally I would let it soak at least overnight in WD40 or other penetrating oil. If it is possible to get a nut on the end then do this and tighten a few turns onto the exposed thread. Then hit fairly hard with a hammer a few times, straight onto the thread. Should shock the thread loose with any luck. If you cant put a nut on the end then try without it but dont knock it too hard so as to flatten the remaining thread and prevent gripping with tools.

Some more info from a recent thread here may be useful...
https://club8090.co.uk/forum/viewtopic.php?t=28174

[andysimpson]

Is this a 1y engine?

[..lee..]

if there`s enough thread sticking out you could weld a nut on the end of it gets good heat in to it.

[big red bus]

best way is to weld a nut over remaining thread and then the heat penetrates the stud and helps loosen it and also you have a nut to get a socket/spaner on. never failed using this method . might not work first time but with abit of patience, will get it out. cheers.

[edoh]

Some other options ....
https://club8090.co.uk/wiki/Te ... bolts/nuts

[Aezmac]

All of the above, or another option, if there's enough of the stud left, is to get 2 nuts on to the stud/bolt, lock them against each other, then try unscrewing the stud using a spanner on the rear nut .

[campervankatie]

After soaking, heating and bashing the stuck stud it finally came out with the help of some mole grips. Thanks for all of the really helpful information.
Since getting my van back from the MOT i have noticed that the headlight is missing the glass. Not sure if it was bashed in or just dropped off.
Does anyone know if this is replaceable or is the headlamp a sealed unit? Also would it be false economy fitting a second hand headlamp?
thanks Katie

[VWCamperfan]

Just dropped off I think, only sealed around edge. Secondhand would be fine, just ensure theres no rusty patches on reflector and you should be ok.