Broken Bolt Extraction
 

Somehow the very back driver's side exhaust manifold bolt on my 95 Z28 LT1 broke off. Any ideas how to extract this without tearing the whole car apart?

Thanks in advance.

P.S. Mods, if this does not belong here, please move it. I put it here because it deals specifically with the LT1 in my Camaro....

Question are you putting manifolds back on the car or a set of headers?

^^ What he said.

If you are putting headers on they will not use the first and last bolts like the manifolds do, they use 2 holes closer to the exhaust port. If its sticking out some just try to grind it down.

If you are trying to put the manifolds back on, shame on you. Honestly the cost of a cheap set of headers may be cheaper than the pain of trying to get it fixed.

I have no desire to put headers on this car, and the manifold is still on the car. I do not know how/why the bolt broke off, but it did...

Oh, so you were not trying to take them off??

Is it leaking?

completly unbolt the manifold and hopefully there will be enough bolt sticking out to grab onto it with some vice grips or something

That's your best option. If there isn't enough bolt sticking out, plan on having to drill into the bolt and using an extraction bit to get it out. You'll probably have to pull the head for that one since it's a little tight between the head and the wheel well.

Don't be afraid to put a torch on the broken bolt, try some penetrating oil first, but don't tear it up too much before heating it. But not too much heat. Remember, aluminum head!!

If it isn't leaking, throw some liquid solder on the sucker and maybe it will hold---get the good stuff. Then sometime down the road if you decide to install headers, you will need to deal with it by drilling the crap out. JMHO.

its a pretty common problem. if you do have to remove it cause your reinstalling mann.s, then you can try a reverse drill bit in a reversible drill. tool rental stores rent 90deg. angle drills that MIGHT work for that back on.
I did that to the bolts in my caprice heads and they all came out (4 of them mo fo's)
you'll have to remove the mann. to access the head around the bolt. you can use a Mapp gas torch available at any hardware store. the idea is to heat all the way around the bolt, but not heat the bolt itself. the alum will expand and release the hold the corrosion has on the bolt. and the drill bit will bite in and turn the bolt. it'll drill in about 1/4" first, then it will just grab the bolt and start turning. make sure your in the center of the bolt though just in case it doesnt turn the bolt and you have to drill it out completely and helicoil the bolt hole.

Yah---probably the JB weld not such a good idea since the maifolds get about twice as hot as the epoxy. Frankly, if the manifolds leak, you are better off just removing the manifolds and putting new bolts after you extract the broken bolt, either with vice grips or drill and easy out.

Non of it is easy because of the limited space to work. Good luck.:cool:

Thanks for the advice guys, we are gonna tie into it this next week and see what happens. It is leaking, that is the only reason that I found the missing bolt...