Broken bolts in exhaust manifold
 

Has anyone forund a good method of removing broken bolts from exhaust manifords? I search past posts and only found one post that was a little helpful and that was a couple of years ago. Maybe some someone more recently had found a good method of extracting the remains of the two bolts. Heat would seem to be the best method, but maybe there is a better way someone has found. Any help would be appreciated.
Rusty Nelson

Re: Broken bolts in exhaust manifold
 

Because the remains of the bolts are usually severly rusted, drilling and helicoiling is the only method that has worked for me.

Re: Broken bolts in exhaust manifold
 

If these bolts are in the block, then drill a hole in them and use an easy-out. It turns backwards so the bolts will back out. John

Re: Broken bolts in exhaust manifold
 

Drill a correct sized hole in the bolt for an easy out, heat it up with a torch and back it out. If it doesn't come out, try some penetrating oil and heat it up again. Once you get it out put a helicoil in it and call it good.

Re: Broken bolts in exhaust manifold
 

If you go the EZ out route heat the area around the broken stud as hot as you can logically get it and light a candle made of parafin wax, and drip the melted wax onto the broken stud. hopefully the area around the stud is still hot from the torch heating. This will pull the parafin wax down into the threads and help lubricate the threads for extraction.

Re: Broken bolts in exhaust manifold
 

I have used left hand drill bits from snap on to remove broken studs don't know about badly rusted ex. studs it's a hard job any way you go about it at the shop were i worked the job of removing broken studs/bolts and repairing was given to me i took my time it took anywere from 1/2 hour to two hours to remove a stud without damaging the engine what ever way you go use caution take your time good luck

Re: Broken bolts in exhaust manifold
 

Use Vince's method. Weld a flat washer to the broken bolt let it cool some, then weld a nut on top of the lockwasher. Often the two heat cycles will break the rust bond, but I'd also go through the exhause ports and heat the two bolt pockets to at least a dull red, then try to back out the welded nuts. This has not failed me yet.

I assume you are talking about the two bolts that hold the two manifolds together.

Re: Broken bolts in exhaust manifold
 

I have made it a yearly habit of exercizing these two bolt's Never siese on the threads.

Re: Broken bolts in exhaust manifold
 

Humble Opinion:

Threw all of mine away years ago.

"Easy-Outs" are made for "easy" bolts, i.e., bolts that are easy to remove.

Here is what usually happens in many cases when using "Easy-Outs" on vintage cars & machinery for trying to remove old bolts which have threads that are severely rusted:

1. First drill a hole in the bolt.
2. Next, insert the "Easy-Out".
3. Then turn the "Easy-out" CCW whereby it enters the bolt hole.
4. As the "Easy-out" goes in farther, it expands the bolt hole & compresses the bolt threads into the metal making it far more difficult for the bolt to turn because of increased bolt thread friction.
5. Then either "Snap, Crackle or Pop", your choice of what you heard when the "Easy-Out" broke in the bolt hole.
6. Now a drill bit will not drill out the high carbon steel "Easy-Out" which is as hard as a file.
7. Finally, either go to a local machine shop or use your welder to do what Tom suggested in Reply #7 above with welding a washer & nut on the bolt.

Re: Broken bolts in exhaust manifold
 

As I am not overly concerned with 100% original I took the easy road and purchased a new set from snyders.

Re: Broken bolts in exhaust manifold
 

LOL:D That's usually a good choice since so many exhaust have a sag near #4 port.:mad:

Re: Broken bolts in exhaust manifold
 

I agree with post #9. Throw away all your 'easy-out's' and use Vince's method. If you use a stick welder, there is a special rod to use for his method. I think I saw it in Granger's catalog.