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Exhaust manifold bolts broke
Topic Started: Oct 23 2014, 12:02 PM (1,328 Views)
freegeo
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For those of you that have removed broken bolts and saved your exhaust manifold. What method did you use and have success with? I know I will have to drill out the bolt but then I won't have anything to grab on to to try and remove it.

Have any of you try heating it up to get the bolt out?

Here is what I have to work with.

Posted Image


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perfesser
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Elite Member - Former Metro owner

A few heat/cool cycles with a torch may break the scale loose that bonds the bolts to the manifold. I would try that first and hope it did the trick. I'd be prepared to escalate, though. The undercut at the manifold of the bolt on the side opposite from the O2 sensor doesn't look promising! Try the other one first and see what happens with it and you'll have a better understanding of what it might take for that one.

If I wasn't worried about absolute originality, I'd probably cut both bolts off flush to the manifold with a grinder, then I'd drill a hole big enough to put a socket-head cap screw through from the top with a nut on the bottom. And I'd use a dab of anti-seize on them where they go through the new hole to make sure they can come out at some future point. Make sure you use the best (preferably carbide) drill bit you can find, because rust is very hard to drill through. It'll kill a bit in a heartbeat!

Good luck!!
Edited by perfesser, Oct 23 2014, 01:19 PM.
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PA.metro,fixer,frames,ect
Frame Fixer

the studs look plenty healthy to me to be able to get out put and advice or hold steady in some way and put the torch heat to the area around the stud where it goes into the manifold and keep vice grip or weld a nut onto the remaining stud and keep steady pressure on it when the manifold is cherry red little bit more pressure and it should move, I have removed many just like that and I've had success on all of them
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Murf 59
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PA.metro,fixer,frames,ect
Oct 23 2014, 05:03 PM
the studs look plenty healthy to me to be able to get out put and advice or hold steady in some way and put the torch heat to the area around the stud where it goes into the manifold and keep vice grip or weld a nut onto the remaining stud and keep steady pressure on it when the manifold is cherry red little bit more pressure and it should move, I have removed many just like that and I've had success on all of them
This and the post above are good postings. Make your first shot the best. Like he said, put it in a vise and heat it smokin ass red hot, then put your best vise grips on it and giver hell.
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freegeo
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Thanks for the advice. All I have is a small propane torch. Just have to try it and see. I can weld a nut to the end to help get it off too.
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fireflyin


u mite need a cutting torch since there much hotter then a propane torch and few whacks with a hammer on the stud works too too loosen them up
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sphenicie


first, the important part of heating is that you DO NOT heat the stud itself, it will twist even easier.

next, when heating doesn't work, drill them out and use bolts. if you feel the need you can tap them and ..........that's a lot of extra unnecessary work. just drill and bolt. I go with a 3/8 hole and bolts, cause I have them on hand. 3/8 x 3 1/2, I think. the one toward the rear of the engine will work with the nut down, the one behind the O2 sensor is easier with the nut up.
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freegeo
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If I can't get it out I'll just buy a new aftermarket one. Found one cheap on ebay, it's on sale.
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freegeo
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Got the one good looking bolt out. Welded a nut to the remaining bolt and while it was still hot put a socket and wrench on it and it came right loose.

Thought lady luck was on my side so tried it on the other and it just snaped right off. Tried drill it out in my buddys drill press. Could not keep the bit going straight. That stuff is hard.

Just went ahead and bought an aftermarket one off ebay. It was on sale for $25. Has to be good enough to use for a while atleast.
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perfesser
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Elite Member - Former Metro owner

:hmm :hmm

$25- vs. several hours of dirty, frustrating time spent dulling drill bits and making up new forms of profanity to express the full intensity of your loathing for that @#$%^&*!! manifold.

I think you came out ahead on that deal!! :D :D
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Good bye


Road salt sucks for car repair, works good on ice though. Left coast is lucky, no road salt.
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