Happened to me and I got a mobile welder to make a house call to try the "welded washer" trick. I had tried getting it out myself with no luck. Drilling in that position was not doable. Weld a steel washer to the steel stump remaining, then weld a steel nut to that washer. Nothing welded sticks to the aluminum head. Turn that nut with wrench to extract. 

Unfortunately, my guy's heart was not in the job and I wound up yanking the head and taking it to a machine shop. I still have faith in that first process and people do swear by it. 

Good luck!

Stephen

Mobile

> On Dec 10, 2018, at 12:34 PM, Mark McCulley <markmcculley@GMAIL.COM> wrote:
> 
> 1987 syncro Westy
> 210K
> 
> Dropped of at mechanic this morning to replace exhaust. Stud broke off in
> one of the heads and they're telling me I'll need to replace the heads or
> put in a new engine. I was going to go with replacing the heads, asked them
> to confirm that the rest of the engine was OK. They measured oil pressure,
> 22psi @ 2000rpm using the VDO gauge on my dash. Said engine was worn out.
> 
> Is there no way to extract broken stud from head without taking the head
> off?
> 
> Mark
> Seattle, WA