I was trying to remove the coolant sending unit from my Trooper when I snapped it off. So, now I have a ~3/4" OD brass tube sticking out of the block. There is about 3/4" of it sticking up. I tried an easy out, but that just ground the brass into a bigger ID.
What do I do next?
If there's nothing left to grab onto, then try left-handed drill bits. Punch a starter hole, start with a small bit, and work your way up the sizes. Drill slowly, back out often, and use lots of cutting oil so you don't snap a bit. I've read somewhere else that melting a plain wax candle onto the broken fastener will get wax into the threads, making them more slippery.
Pipe wrench.
I managed to get another ez out into the brass plug, but it is still so tight I'm breaking wrenches on it. Any ideas to loosen it? I've tried heat and screw loose.
I'd soak it in PB blaster. Let it sit then spray it again and try it. Acetone and trans fluid is as effective as PB. Can you grind a flat spot to get a punch to tap on it counterclockwise?
Wow! Even a half inch impact won't budge it. Ideas?
Breaker bar and a cheater pipe.
Use the least amount of extensions possible on your impact. They will eat up a ton of torque. You may just soak it in a penetrating compound then let the impact hammer it in for a good while.
I left it to soak overnight, tomorrow is another day. :D
Put a hacksaw blade on the grinder and grind it down to fit inside the pipe. Carefully saw the fitting at 1,6 and 10 o clock. (basically thirds) If you are careful to take only brass you can knock out the fitting with a cold chisel(in thirds) and use teflon tape + neverseeze to reseal new fitting.
Pipe wrench, leave ezout in for support. Clamping action of pipe wrench will collapse tube in its bore slightly and break it free.
From what you're describing, it's stuck so bad that anything you use without some temperature action is only going to break it again...so don't do the job without it.
^^ also if you arent using at least MAPP gas it's not hot enough
Agree with the cutting it.
Remember, the ezout is pushing outwards on it, expanding it a bit, making the fit even tighter.
Worse thing in the world is to have the ezout snap off in there. That is not fun.
If there is still a bit sticking out, you may have success with slotting it and placing a big screwdriver across the slots. Though more likely you'll just tear it.
Wouldn't have happened on a Cherokee! (Sorry, couldn't help myself! 
)
Remember, lefty-loosey, righty-tighty...
Stop.
Can you just abandon it in place and use one of these instead?
As long as it is not leaking Woody has the best idea. Otherwise do what TRoglodyte said and cut it out.
I would apply LOTS of heat and then try to remove it.
TRoglodyte wrote: Put a hacksaw blade on the grinder and grind it down to fit inside the pipe. Carefully saw the fitting at 1,6 and 10 o clock. (basically thirds) If you are careful to take only brass you can knock out the fitting with a cold chisel(in thirds) and use teflon tape + neverseeze to reseal new fitting.
This needs quoting. It's time consuming as hell, but it will get it out without damaging the threads if you are very careful.
Jere managed to get it out for me today with a Dremel. The new one is installed and working great!
How did he use the dremel ?
I'm guessing the cut a slot + use flathead screwdriver method.
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