The best thing to do is to go ahead and try to get them out, if you twist them off, fine, if not then your good to go. That said, you can heat and quench the bolt with causes it to expand and then contract, often breaking the rust free if your lucky. If not it also helps to heat the housing which causes it to expand away from the bolt, also breaking the rust's hold if your lucky. Too, heating the housing soaking it with penetrating oil, and then smacking the head with a hammer a few times will often break the rust free.
Hopefully the bolts will at least move and break free from one of the above proceedures. Getting them broke free is good, but it's still no guarantee they ar going to come out. Once 'broke free' work them back and forth loosening and tightening them, while keeping them soaked with penetrating oil, so it wil wick it's way into th threads and help them come out easier.
If they break off, grind them fluch with the housing and then use a center punch to mark as close to center as humanly possible. Once marked use a small bit, like a 1/8" to drill a hole through the broken piece. Then step the bit up in size in small incriments until you either get the piece to break free with an easy out, or you get it thin enough to see the tops of the threads. If you get it to that point use a small, sharp, Cape point chisel to collapse the piece. Once collapsed the piece should come right out.
I've done many, many bolts like this over the years, including quite a few in the head of various diesel engines that had rusted off, or broken, off when removing the exhaust manifold. The only thing I do different is that when it's clear an easy out isn't going to work I use a die grinder and a carbide burr to eat away at the broken piece until I can collapse it.
Any way you go it sounds like alot of work, but if your careful it will always be a royal PITA but it's not nearly as hard or complicated as it sounds. Eventually you'll get to the point, like me, that you cuss and fuss about it a bit but when the piece comes out and the threads are still in good shape, the satisfaction of a job well done is all that matters....
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Today's Featured Article - The Niagra View Mobile - Powered by a 1959 Ford Tractor - by Mark Massey. In 1959 the Niagara Frontier Transit Inc. of Buffalo, New York designed and built six Viewmobiles for the Niagara Frontier Sightseeing Inc. for use as a sightseeing ride at the Niagara Falls State Park, Niagara Falls, New York, powered by a 1959 Ford 611 Tractor.
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