I'm replacing the head gaskets on a 98 OB. One of the cam cap bolts broke off in the head. Any helpful ideas as to how to remove the broken part of the bolt that is still in the head.

The only way to get out a broken bolt is to drill down its centre far enough that a bolt exractor can be wound in, and then turn counter clockwise to wind out the broken section. I've done it many times over the years, but never on a head in the engine bay.

 

I suggest removing the head again, and using a drill press try the method I stated. Its a scary job, but you really don't have another option. Take it slow and be cautious. Be sure to buy a GOOD bolt extractor. Cheap ones often break off in the bolt making the job even more troublesome.

 

If you're inclined to not want to tackle the job yourself, a good machine shop should be able to do the job. Good Luck!

if you decide to drill, use a left-hand twist drill - might loosen the bolt as you drill, if not, you can still use the extractoer.

 

 

or try one of these if the bolt isn't flush;

 

http://www.amazon.com/Mayhew-29895-Stud-Extractor/dp/B000XSCDEA/ref=wl_it_dp_o_pdT1_S_nC?ie=UTF8&colid=IDEFQ97CY9SH&coliid=I3NLVZJOIHS95F

 

http://www.amazon.com/Sunex-2-Inch-Piece-Metric-Puller/dp/B00063Z77W/ref=wl_it_dp_o_pC_S_nC?ie=UTF8&colid=IDEFQ97CY9SH&coliid=I2EAIANO5QBDJC

 

http://www.amazon.com/Titan-Stud-Puller-Drive-Model/dp/B00265M8N4/ref=wl_it_dp_o_pdT1_S_nC?ie=UTF8&colid=IDEFQ97CY9SH&coliid=I1X03Z6XADUQ47

I went back to the shop that resurfaced the heads and they said they could dip it in a tank of solution and zap it with electicity to extract the bolt. Then they would put a helicoil in. All said and done it wuld cost more than $100. So I just went to the junk yard and pulled one off a car with the cams and lifters for $46 including core.

 

I did try to drill it out with an extractor drill bit, but it broke. I'll look around to find a good quality extractor bit and try again.