Impossible to remove, just how seized do these get? I used a pipe wrench and turned in a CCW direction until the thread piled right off.
Has anybody attempted to remove these?

I'm afraid to apply any more pressure I feel that the aluminum thread might get damaged.

 

PM Howru he had a similar problem maybe he can help you

 

since you've already trashed the threads, have you tried using and ez out?

 

Ez out...I'm not familiar with that, the pipe wrench did some digging into the metal as you can see from the pic.

 

EZ out is for when its broken off flat with the housing

for the OP-- use a propane torch to loosen the stud before having another crack with stilsens

else there is actual stud removing tool that locks onto the thread and allows you to do this less painfully without risk to the threads

 

get a big pair of vice grips and lock it on as tight as you can get it. then rotate it back and forth, if you keep going in one direction it'll just eventually snap off. back and forth. aluminum corrodes like a sonfoa when it contacts steel. you just have to break the corrosion then once it's moving 2 steps forward, one back.

if you break the stud off then you'll have to pull the motor. drill in the exact center of the stud. then try using an easy out. more then likely you'll have to drill it out until only the threads of the stud remain, then use a pick to work them out.

 

Clamp on vice grips. Heat stud to red hot. Twist out.

 

that does work but seeing that it's so close to the coolant seals might be a little careful with that torch... might go rushing into a rebuild.

 

With the torch I belive it will strengthen the stud a bit more allowing it to come out more easily.
On another note, here is a posting on ebay a guy selling a pair of studs. Unbelievable that someone be selling a pair of used studs, yetalone the guy was lucky enough when he was removing them.

http://compare.ebay.com/like/1903151...=263602_304662

 

I'm not a metallurgist but i believe these stud tend to break due to them being heat cycled so much. heating it removes the hardness, less brittle less breaking. to normalize the stud you'd have to heat them to 750*C (i think) then slow cool them buy wrapping with insulation or burying them in sand.

heating them will also make them expand, the surrounding aluminum expands faster so putting a little bit of heat into the aluminum might not be a bad idea but be very careful not to over do it.

 

Thanks for your input....
The stud came off by using the torch method.

 

Torch always works.... Sometimes bolts may have old locking compound on them that needs to be heated up to soften, or corrosion.