I broke a bolt when removing the exhaust manifold. What happens if I replace the manifold without replacing the broken bolt? OR is there an easy way to rig it so it works without having to try to remove the bolt?.
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Thank You for any help on this.
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...Squddle...

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1999 3.0 Manual Transmission Stepside
1994 4.0 Automatic Transmission Stepside. Project Truck

Sucks to be you....

It WILL leak if you replace without removing the broken stud and replacing. Try welding a nut or something to it and removing it if you can, but other than that, I dont know

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Drill out the center of the bolt and get a bolt extractor tool

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That doesn't sound like a very good idea

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95 Ranger XLT 4x2 2.3 I4 5 speed 206,000 *dead*
96 Ranger XLT 4x4 4.0 V6 5 speed 173,000 *alive*
D35 front, 8.8 rear, 3.73 gears, limited slip rear diff

Yeah, you're going to want to get that out of there. If it's broken flush with the head, drilling it out and trying an EZ out, or drilling it out and re-tapping the hole might be the only options.

If there's enough tread sticking out for you to get two nuts on it, you can put the nuts on, tighten them against each other, and then try to back the stud out.

When I did my engine swap, a couple of the studs broke off, but since I was putting a new engine in anyway, I just bought new studs for the new engine. Didn't have to remove the broken ones from the old engine.

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2000 Ford Ranger XLT
Extended Cab
3.0 Flex
4x4
Manual Transmission
Offroad Package

Welding a nut on the end of a broken bolt actually works very well most of the time if you get a good weld to it, only problem there is with the motor in the truck room is limited and that goes the same for an EZ out also

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2007 F-150 SuperCrew Lariat
2003 Explorer front end swap, 7/8 drop, 2.3L 5 speed 4.10's LSD
2007 Yamaha Dragstar

Hence why it wouldn't be a good idea
push I bet the bolt is flush with the manifold so welding would be hard

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95 Ranger XLT 4x2 2.3 I4 5 speed 206,000 *dead*
96 Ranger XLT 4x4 4.0 V6 5 speed 173,000 *alive*
D35 front, 8.8 rear, 3.73 gears, limited slip rear diff

I actually saw a YouTube video of a guy welding a nut to a stud broken off flush (actually it was cut off for demo purposes). He very carefully "dripped" wire weld into the hole of the nut which was centered above the broken stud. Gradually built up until there was a "bead" at the top of the nut.

However, this would only be feasible if working on a head on a workbench.

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1999 Ranger XLT 4X4 AT Stepside 4.0L

You realize this is 7 months ago ?

Yes. I imagine the OP already solved his problem but there are folks like me who search the archives when dealing with thorny issues like broken studs.

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1999 Ranger XLT 4X4 AT Stepside 4.0L

Howdy!
OP here! It's been awhile since I've been on here. I ended up selling the project ranger. I was in the process of moving and the new place didn't have a garage until I sell this house to buy the garage for the new place. So, instead of having something I can't work on outside and rusting away, I just sold it for $500. the body was in great shape and I already had the transmission out. It needed a new or rebuilt one. I just didn't want to have to remove the motor to get to the broken stud.
Thanks for all your suggestions, though!

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1999 3.0 Manual Transmission Stepside
1994 4.0 Automatic Transmission Stepside. Project Truck

If the thread is still sticking out try some locking pliers to unscrew it out, thats what we did for my brothers headers on his trailblazer SS that had broken head bolts otherwise you may have to weld a nut to it to get it out

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2001 Ford Ranger 4x4 Off Road 4.0L Steppy
Cooper Discoverer MTP 285's
Retrofit Projectors
Bilstein 4600's
#1 bars and 4.10 Open