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Hi. I have had this happen before. I usually weld a nut onto the broken stud and then use a socket to remove the bolt. It often takes several tries until you get a good weld.
That is what I mean, when it is flush. You fill the nut with the weld and it welds to the broken stud. The reason his works is because the weld does not stick to the aluminum. Just the steel of the bolt.
I also believe the heat of the welding helps to loosen the bolt as well. I have been through about 20 nuts sometimes doing this. But it pretty much always works.
I hold the nut up to the stud with a pair of long needle nose pliers.
Any luck getting the bolt out? Please rate my assistance if I have helped you out. Thanks.
You could try drilling it. I have yet to have to do that. You will need a good bit because the metal of the bolt might be hard now since it has been heated and cooled a few times. But I would do that next, then take the timing cover off if needed.
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