Broken exhaust manifold bolt

[Chief Master Sergeant]

I decided to go ahead and replace the rusted our exhaust manifold before installing the new exhaust. The last darned bolt broke off right flush with the head. There's not enough room to get a drill in there, so i wondered if I should just not worry about it. It's the very front passenger side bolt.

 

[jim3326]

I would drill it out, unless you like the sound of if it;D Try to round up a 90* drill and use a stub bit, it should just fit. You might also try to jack that side of the engine up a little also.

Jim W.

 

[jw0747]

base hobby shop got one of these

 

[rastiss]

base hobby shop got one of these

angle head drill FTW! dont forget to center puch.

 

[brianstrange]

Do you have a welder? Try welding some wire strips to the stud, then twist them together to the point that it unscrews. I've seen studs come out very easy this way.

 

[Chief Master Sergeant]

I just hit up Harbor Freight Tools. We'll see how it goes.

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[broncnaz]

Heck at least its not the very rear drivers side. Needs to come out or you'll have a annoying exhuast leak.

 

[Chief Master Sergeant]

What an ass pain. The bolt was rusted pretty good. Used left hand drill bits, but they wouldn't spin it out. End up drilling it out as deeply as I could before the cheap drill broke. Used a tap to reset the threads, but I'm not sure how deep it is. Just added washers and tightened her down. I think we're good. Thanks for the help.

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[muskrat]

I'm installing my new BC Broncos headers on Saturday. I hope to avoid the broken bolt! Did u soak them before loosing them?

 

[Kegger]

This may sound dumb get the motor to operating temp and crack the bolts loose. where gloves, like a torch.

 

[Chief Master Sergeant]

I used PB Blaster before, but hard to get it to the bolt through the manifold. Too pressed against the head.

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[KyleQ]

I prefer welding a nut to the bolt and trying that extraction method before drilling. I recently did this on my 95' F150 with shorties on it - poor exhaust hanging (or lack thereof from the PO) put lots of stress on the header bolts and broke one off flush. 5 or 6 attempts with the welder got the job done.

Glad to hear you were able to drill it though-