Do you need to put any kind of sealer on an intake manifold gasket?  I have to drill out the stud from the EGR valve... Tried heat & vise grips, pb blaster, seafoam creep, hammering it a little bit, and even one of those fancy stud removal tools.  Now it's down to about an M4 bolt and the thing is stuck... I think my only option is to take off the manifold and drill it out... Let me know if there are any more suggustions out there... I am going to try one more thing... I'm going to dremel a little slot in the stud and try to screw it out... we'll see what happens.

Thanks...

ERock

You said you tried heat , but I find stuck bleeder valves, brake lines etc usually come loose if I heat them up red hot then dose them with water. I think the expansion and quick contraction that helps to break it free. It's worth a shot if you haven't tried it yet.

You said you tried heat , but I find stuck bleeder valves, brake lines etc usually come loose if I heat them up red hot then dose them with water. I think the expansion and quick contraction that helps to break it free. It's worth a shot if you haven't tried it yet.

ditto, the key to using heat is to get it RED hot (orange hot actually... )

Be careful not to melt it...

BUT, remember that heating it to red hot, and dousing it with water will harden the bolt, and make it nearly impossible to drill, unless you anneal it again by heating it hot and letting it cool slowly... just a thought.