Apply heat to the stud if possible. When it expands, it will break the rust seal and can be backed out. A good way to do this is by welding a nut to the stud. The heat from welding will break it loose, even if the stud is a littl below the surface, the weld will not stick to the cast block.
You don't usually even have to wait until the stud is cool to back it out.
If a welder is not handy, and the stud is sticking out, heat still helps. One caution. I have burned penetrant which I had worked into the threads by too much heating on a really bad broken bolt which made it much tougher to remove, so after I've heated one I don't apply penetrant until I'm pretty sure I'm done heating. I also like to put penetrant on with the bolt hot so it goes in easier.
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Today's Featured Article - When Push Comes to Shove - by Dave Patterson. When I was a “kid” (still am to a deree) about two I guess, my parents couldn’t find me one day. They were horrified (we lived by the railroad), my mother thought the worst: "He’s been run over by a train, he’s gone forever!" Where did they find me? Perched up on the seat of the tractor. I’d probably plowed about 3000 acres (in my head anyway) by the time they found me. This is where my love for tractors started and has only gotten worse in my tender 50 yrs on this “green planet”. I’m par
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