9) Alright... system is now removed. Like most people you now have broken bolts to deal with. These bolts are compliment of GM and they stick in your aluminum head. If you're lucky the stud is sticking out of the head. Use vice grips or a stud remover on a ratchet. If you're not lucky the bolt is inside the head. Couple of choices.... drill it and easy out it, or research ways to weld a nut on the bolt to ratchet it out with a socket.
I had one broken bolt, drive side closest to the firewall. There was a VERY nice stud sticking out and I just happened to remember I had this bad a*ss stud remover kit from Sears. AWESOME...right??
Ya.. it was awesome until I took two turns of the ratchet and the damn bolt snapped again.. YES.. again. A second time. So this one bolt snapped twice. Second time inside the head. Great. I was very fortunate to have a buddy over with more experience in this area than I.
We had to remove the fender well heat shield, use a drill bit with a hex end so it would fit in a socket. This socket was attached to 18" of 1/4" extension in order to reach the bolt on the head. I've heard people say right angle drill to get these busted bolts out.. I don't see it. No way.
My buddy drilled the perfect hole in this busted bolt, and then used his snap on extractor to back it out. Couldn't believe how great it turned out. Check out pics of the bolt. Two pieces... the one piece is the one I busted off with my stud remover (I was literally using the strength of my thumb!) the other piece is obviously the piece my buddy rock star drilled.
I don't have any pictures of the drill setup we used, but it's no different than the ratchet setup in other pics. A lot of length and a dead straight aim. To put in perspective the drill was outside of the fender well.
Old bolt next to new bolt - Fastenall M8-1.25 x 30mm DIN 6921 Class Class 90 Yellow Zinc Serrated Flange Bolt --- Thanks NJH2!!
