1991 Volvo 240 sedan with AT, 168K. Started having intermittent stalling issues, FP relay is good as is fuel pressure. The crank position sensor wiring was looking bad so decided to change that out. The bolt head snapped off during removal! Any suggestions on how to remove the broken stud? As you know, it is pretty tight in that area.

Harbor freight right angle drill. Spring loaded center punch. Patience.

Stabbing an auto transmission on a 240 is the most miserable job on a 240. Even worse than removing the dash. I did one 250 miles from home in an abandoned service station pkng lot. ( The worst 16 hours of my shade tree mechanical career ) The setup of the underside of the car fights the alignment. Remember though, that a mechanic would have to charge you 300 to 600 dollars to do the job. Success will save you big bucks.
Consider installing a helicoil in the crank sensor screw hole, and dont tighten it too much, unlike the person who put you in this predicament. Also, go ahead and consider your center bearing, shift linkage grommets and u joints. Good luck to ya. You can do it.

Very carefully, if you break the CPS mount the transmission has to come out to replace it! Start soaking with PB Blaster and be patient.
Dan

Ugh, off to HF I go....I was hoping it was not going in that direction