8.1 Workhorse exhaust bolt broken

Thanks for the replies. I've decided to try the Kral clamp specifically designed for this issue. For $42 it will be worth it if it works till another stud breaks. Then it will be
time to remove the head I reckon.

As already noted. The easy way is to remove the manifold. Then hit the stud on the end with a hammer. That will shake it loose. Clamp on with vice grip and take it out. Those advocating changing the manifold gasket are at least 30 years out of date. Exhaust manifold to head gaskets are a thing of the past on OEMs. Before reinstalling the manifold, have it surfaced at the local machine shop. Then rub the exhaust ports down with a wet stone and mineral spirits, to clean them.

Richard

I have had good luck with Grabits on Ford V10 broken manifold studs.

Grabits

It's not likely you can drill it out with any success. The way I've done it before is to remove the manifold and sometime there is enough of the broken manifold bolt sticking out of the head to get vice grips on and turn it out, but if not enough sticking out, place an oversized nut over it and then spot weld through the nut to the bolt. Let it cool for a few moments and then turn it out. If the broken bolt is recessed into the surface of the head you will probably have to remove it and take it to a reputable machine shop.

I have heard that the kral or dorman brackets work well if the gasket is not blown completely out. I would like to put them on my 6.0l as a preventative.

Bolt is broken below the surface, no chance of grabbing it with anything. Leaks only on start up for about 2-3 secs then is fine. Don't know how long that will last though.

Is the bolt flush with the manifold? It's going to be difficult with the manifold in place. Is the gasket leaking? Any cracks maybe best to remove or replace the manifold?