Engine/Transmission (1994 - 1998) Exhaust manifold bolt snapped off in the head

[TORQUED TAYLOR]

Well, it finally happened to me. The bolt nearest the firewall snapped due to the dreaded manifold shrinkage and the end of the damned bolt is in the head. Help. :{

How do I get this thing out?



Thanks in advance,



JT

 

[McCRam]

A good drill bit, and an extrator would be where I would start. Is there any bolt at all showing? Try to get a bite on that if you can with vise grips. Start spraying it with penetrating oil now. I got a few out a couple months ago that only had a 1/16 inch sticking out. I cut a slot in them with a dremel and got them out with a screwdriver. Hopefully it doesn't fight you to hard. Good luck.

 

[6btsmoker]

after you drill the bolt , if the sucker will not back out with an "easy-out" , try running the engine up to temp and then try the "easy-out" agin. this method has helped me in the past. good luck.

 

[FATCAT]

1st, order yourself a new ATS manifold (and gaskets).

Then, when it comes in, remove all the other bolts from the old manifold and try to slid the old one off over the snapped bolt.

Then you can just put a vice grip on the broken bolt (should be a inch or so sticking out), and remove it.



Then put on the new ATS manifold and you won't have to worry about it again.



I just had the ATS put on my truck last week cause the old bolts were bending pretty bad and the old manifold had shrunk about a 1/4"!!!

 

[TORQUED TAYLOR]

The problem is that bolt snapped just below the surface of the head so I can't get anything on it. It's probably recessed 1-2 threads deep and because it's so far back toward the firewall I don't think I can get an easy out on it. Tomorrow morning I'll spray some penetrating oil on it and hope for some more sugestions.



Again thanks for the help guys, I appreciate it.



JT

 

[Reb.B]

should have spent the money on the three piece, but at least it didn't brake the ear off. I've seen the one in the back brake before. Here's the steps to get it out. buy a three piece manifold, spray BP blaster (yellow can and yellow top, get a sharp punch and make a deep dimple, and then start hitting it counter clockwise. If this doesn't work, get a right angle drill that has reverse and get a reverse drill bit. Try this first before the screw extracter. If this doesen't work then get a screw extractor, onlt a swirl one, don't brake it, if that doesen't work then drill it out a heli-coil it. It's been done before and it will work fine. Good luck.

 

[biggy238]

I too would find a reverse hand drill bit and a 90* drill (for clearance) and start drilling at low speed. Hopefully it would catch and bring the bolt out enough to be worked with.

 

[TORQUED TAYLOR]

I'm shopping for a 90* tomorrow and hopefully this thing will come out.



Thank you for the replies.

 

[Reb.B]

make sure it has reverse, some don't. Good luck!