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Author Topic: fixing broken exhaust manifold stud in head  (Read 14746 times)

Offline gold84gmc

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fixing broken exhaust manifold stud in head
« on: July 11, 2009, 06:50:46 pm »
im thinking about putting headers on my truck..it has the original exhaust manifolds i know theres probably nothing you can do to make sure that bolts dont snap when removing them but if it does happen what could i do to fix it or get the broken part out of the head?
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Offline 4x4orbust

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Re: fixing broken exhaust manifold stud in head
« Reply #1 on: July 11, 2009, 08:24:29 pm »
i just went through this,  you can drill and re-tap the holes, just make sure you don't go to deep, turns out there's a water jacket about 1/4" past the end of the holes. (don't ask me how i know)  try an ez-out first, just don't snap it.    first try turning the bolts by using a punch and hammer.  good luck
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1982 chevy K-10 SWB, 355 th350/np208. 2.5"lift, 33" swampers, headers/duals,  current project

Offline Donut

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Re: fixing broken exhaust manifold stud in head
« Reply #2 on: July 12, 2009, 08:14:04 am »
When I pulled mine, I cleaned up everything the best I could and made sure I could get a socket on the bolt head.  Then I "cracked" the head of the bolts with a hammer, (just a quick tap, to help break loose the rust).  Soaked them down with the WD for a few days.  Grabbed a 4 leaf clover, rabbits' foot, my lucky penny and they came right out. ;D

Where in Maine are you located?
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'73 Chevy K-20 ***SOLD***
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My plow was half price if i took the truck with it.

'86 C-30 dually, 454/tbh400

Offline gold84gmc

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Re: fixing broken exhaust manifold stud in head
« Reply #3 on: July 12, 2009, 10:06:16 am »
Quote from: Donut on July 12, 2009, 08:14:04 am
When I pulled mine, I cleaned up everything the best I could and made sure I could get a socket on the bolt head.  Then I "cracked" the head of the bolts with a hammer, (just a quick tap, to help break loose the rust).  Soaked them down with the WD for a few days.  Grabbed a 4 leaf clover, rabbits' foot, my lucky penny and they came right out. ;D

Where in Maine are you located?

i guess ill try that too lol...im in monmouth in between augusta and auburn..where are you in maine
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92 buick century custom 3.3L

Offline Donut

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Re: fixing broken exhaust manifold stud in head
« Reply #4 on: July 12, 2009, 04:36:46 pm »
Personal message incoming. (nevermind, your inbox is full)

I'm just the other side of Augusta.  (Whitefield)
« Last Edit: July 12, 2009, 04:45:24 pm by Donut »
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'73 Chevy K-20 ***SOLD***
350/tbh350/np205
My plow was half price if i took the truck with it.

'86 C-30 dually, 454/tbh400

Offline gold84gmc

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Re: fixing broken exhaust manifold stud in head
« Reply #5 on: July 12, 2009, 08:22:14 pm »
Quote from: Donut on July 12, 2009, 04:36:46 pm
Personal message incoming. (nevermind, your inbox is full)

I'm just the other side of Augusta.  (Whitefield)

i just emptied it...sweet i thought i was one of the only people on here that was from maine and your pretty close to me
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92 buick century custom 3.3L

Offline 84chevysilverado

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Re: fixing broken exhaust manifold stud in head
« Reply #6 on: July 14, 2009, 02:12:45 pm »
when i put headers on my truck I broke 2 bolts off inside the block had to drill them out and re tap them. take your time and it will work fine. Just remember that the new threads wont be as strong as the original so dont tighten those bolts as much
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Offline Laderhosen

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Re: fixing broken exhaust manifold stud in head
« Reply #7 on: July 14, 2009, 05:58:04 pm »
I've heard having the engine hot can help.... Anyone know if there's any truth to that??

I've gotta do mine soon too, keep putting it off cos I'm scared of snapping the bolts!!  ::)
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Offline frogman68

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Re: fixing broken exhaust manifold stud in head
« Reply #8 on: July 14, 2009, 06:03:12 pm »
Quote from: Laderhosen on July 14, 2009, 05:58:04 pm
I've heard having the engine hot can help.... Anyone know if there's any truth to that??

I've gotta do mine soon too, keep putting it off cos I'm scared of snapping the bolts!!  ::)

I would say yes, it works (and if I am not mistaken haynes has it listed in their manual) for the oxygen sensor
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Offline 4x4orbust

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Re: fixing broken exhaust manifold stud in head
« Reply #9 on: July 14, 2009, 06:37:04 pm »
i was told the same thing about the hot engine.  i had tried it, but it didn't help much.  or maybe it did, a few more came out than i thought would.  as i said, be careful if you do drill the bolts out,  be sure to mark your depth so you don't go to deep... (says the guy with new heads)
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1982 chevy K-10 SWB, 355 th350/np208. 2.5"lift, 33" swampers, headers/duals,  current project

Offline gold84gmc

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Re: fixing broken exhaust manifold stud in head
« Reply #10 on: July 14, 2009, 07:02:55 pm »
if you do have to drill new holes and re tap them what size drill bit should you use and how deep should the hole be?
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92 buick century custom 3.3L

Offline 4x4orbust

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Re: fixing broken exhaust manifold stud in head
« Reply #11 on: July 14, 2009, 07:38:46 pm »
i used a 5/16" drill bit, followed by a 3/8-16 tap.  (i center punched the broken bolt, then drilled it out, using the tap to re-claim the threads already there)  the hole is approximately 3/4" deep.   maybe 7/8",  if you get one of your bolts to come out, stick something in there untill it bottoms out to be sure. 
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1982 chevy K-10 SWB, 355 th350/np208. 2.5"lift, 33" swampers, headers/duals,  current project

Offline Laderhosen

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Re: fixing broken exhaust manifold stud in head
« Reply #12 on: July 15, 2009, 03:59:59 am »
So definately don't get on there with a cold engine and an impact gun!!!  :o

I've heard from a guy at work about a new penetrating oil that's supposed to be the best thing since sliced bread! I can't remember what it's called now, keep meaning to find out. Supposed to be better than WD40.
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'82 3/4 ton, 350, th400,
'88 K5 Blazer, 350, 700R4
’98 BMW 328i daily drive
’91 VW Golf Mk 2 with VR6 conv

Offline gold84gmc

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Re: fixing broken exhaust manifold stud in head
« Reply #13 on: July 15, 2009, 06:29:24 am »
Quote from: Laderhosen on July 15, 2009, 03:59:59 am
So definately don't get on there with a cold engine and an impact gun!!!  :o

I've heard from a guy at work about a new penetrating oil that's supposed to be the best thing since sliced bread! I can't remember what it's called now, keep meaning to find out. Supposed to be better than WD40.

its not new but pb blaster? ive also heard that aero kroil is even better
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92 buick century custom 3.3L

Offline maddog

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Re: fixing broken exhaust manifold stud in head
« Reply #14 on: September 05, 2009, 06:53:53 pm »
Here is a trick I used before sometimes it work and others well we all know those times.
With engine cold heat head with mapgas right by bolt, have on hand some simple wax, let wax pull in around manifold, I know a lot of you guys are thinking WHAT but it has worked for me better than any WD, it really works good if bolt is exposed.
Try it on something else once, old timer taught this to me now I'm the old timer. 
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