I think those things are an oxymoron, they just make the job harder when they snap and you have to drill them out.

 

One definitely won't work on something like that pic, but I've used them successfully several times. It's all about having the larget possible sized hole, made straight.

People think they are for quick extractions. While many are marketed that way, they are not. They are for removing the final last bit of bolt shaft and threads after you've properly drilled it.

Sure, if it's not too stuck you can get lucky with them, but that's not really what they are for. And if you break one off in there, you've just made the job even more difficult, because you left a chunk of tool steel in there.

Like everything else, you need to know how to use it to be successful.

 

No, even with the pan off, there is no clearance. I am fine with taking the pan off again, but it will only give me about a 1/4" more clearance. I may end up removing the pan anyway.

I can get a straight shot at the end of the extractor regardless of the pan.

 

Ok, I retract (at least temporarily) my 'blood suckers' comment. I contacted the dealer today and discovered the replacement clamp is only $3.37! Now, if I can just get that stud out....

 

+1...I'm definitely not a fan of ez-outs...

I can't offer any suggestions that haven't already been put forth, but I do wish you luck. Now that you've confirmed the clamp isn't going to cost you a fortune, please let us know how this goes for you.

 

Looking at your pictures there might be a plan "C"
If there is enough sticking out you could run a thread chaser on it, then cut a little off each side of the hold down to make it slide on farther then screw a nut on.
might save you from plan "D"

 

Ok, I finally got the parts and tools together and got a chance to get under the truck. I drained and removed the sump, put the stud extractor on the end of the remnant of the bolt, and she popped right out. Slick as that!! See the pics of the extractor and the bolt remnants below.

I installed a new filter and gasket and replaced all 6 of the bolts with M6x1.0 SS allen-head bolts. The allen-heads are easier to work with and as they only require 8 Nm of torque, they are plenty strong enough. Also, the SS is less likely to corrode in the aluminum. All that aside, they look damn cool!!

 

Yes stud extractors are a nice tool to have around, how much did that sucker run you? It's a german tool correct?

 

Correct - good eye. $24 and worth every penny.

 

Well done! I am glad to see that you worked your problem out. That can be really frustrating. Even with the purchase of this tool you still saved money compared to bringing it in for service. Did you end up getting the dealer bolt and bit to finish up the job?