Intake manifold removal--Advice needed

[solve4x]

So far, so good on removing the intake manifold (87 R10 305 2wd) to replace the gasket.
...Well, until the head snapped off the bolt, in front near Cylinder#1.

Questions:
How do I deal with the headless bolt?
How do I lift the manifold to break the old gasket seal? (Haynes says there's a "lug" to pry on...I don't see any such thing)
Can I lift the manifold with the broken bolt in place?..since it seems to not be threaded in the manifold.

Less important question...Do I need to take the valve covers off?  Haynes says to, but it looks like there's room to lift the manifold out with them on.

This is a major project for a newbie like me.  I built some confidence redoing the whole front brake system.   The intake gasket is the other big issue...any advice appreciated!!!
Scott

[rich weyand]

Soak around the bolt with Silikroil or a 50/50 mix of acetone and ATF overnight, then use an Easy-Out to get the bolt out.  You drill a hole down into the bolt first, then you tap in the easy out and wrench on it.  It is tapered and has a left-handed spiral ridge in it that grabs the inside of the hole and tightens into the bolt as you try to turn it out.

http://www.amazon.com/piece-Easy-Screw-Bolt-Extractor/dp/B0002UJNWE/ref=sr_1_1?ie=UTF8&qid=1381023912&sr=8-1&keywords=easy-out

[Stewart G Griffin]

1) the broke bolt thing was pretty much covered by rw.
2) i think you can just get a screwdriver in between the block and intake and pry there---gently.  i don't remember if you have to take the valve covers off or not?

3) The phrase, "If you don't have anything nice to say......."  applies for me towards Haynes.  Although they are better than Chilton's.    Try getting a service manual---they are not that expensive.

Also, have you tried How to rebuild your sbc by David Vizard?   Or rebuilding the SBC?    These books can really help you here.

[HAULIN IT]

Remove all of the rest of the bolts & then slide a thick putty knife or screwdriver in between the block & intake on the Right side. It all depends on how close to the head the bolt broke off...right below the head may be a problem. If it's near the head surface, you should be able to lift up on the Right side & slide the intake away from the bolt. Once the intake is out of the way...decide on the best plan from there to remove the bolt. Lorne

[Boone83K10]

Easy out will get the bolt.

You do not have to take off the valve covers to lift the intake manifold. Make sure you use gasket maker ob the front and rear surfaces, not the gaskets that come with it.

[solve4x]

Thanks all!
Got the tools...we'll give it a try.

[solve4x]

Update--The intake manifold is off...an old wood chisel made a great seal breaker.  Still dealing with the bolt; it's frozen in there good.
Thanks for the tips!
Scott

[rich weyand]

Don't forget to soak that bolt in Silikroil, or even better 50/50 acetone and ATF.  That will penetrate right down to the bottom of the hole and lubricate the threads so the easy-out can get it out.

[81_Chevy]

the 50/50 mix that rich mentioned is THEE best idea ever. works wonders on stuck bolts.

[rich weyand]

Careful, though.  Acetone is flammable.  VERY flammable.

[solve4x]

Alright--That's worth a try.  11 of the 12 bolts came out easy....that last one is hanging on tight!