Has anyone else had there exhaust manifold bolts break. Both sides in the back of the motor... Is this a design flaw?.. seems to me it is considering (a) Aluminum Head (b) Cast Iron Manifold (c) Holes that are too small or bolts that are too big. Plus+++ add heat and the little suckers pop off like popcorn.. can anyone directme on how they would remove them... BTW I am a Machinist... so I'm pretty good with a wrench... just can't see the bolts... if anyone has any ideas on how to get these out it would help me alot...


Thanks

 

Remove starter, dipstick tube, alternator, air fittings, EGR connection, manifold and install NEW HEADERS.

You'll have to take the manifold off to put a new stud or bolt.

 

IF you are lucky,they arent broken flush or inside the head.You can remove the manifolds and use vise grips to get them out.Otherwise you will have to drill them with a right angle drill(if possibe)Use a left handed bit so it will loosen the bolt as you go (hopefully)Or usae an easy out.If you still cant get them,pulling the heads is needed. Or the above is an alternative.

 

I plan on doing just that... one problem.... I Still Have A Bolt Stuck in My Head!!!

soooo...

 

There is another threaded hole outide your broken bolt that headers bolt up to.

 

I will give that a try... I'm a little nervious about drilling somthing I can't see... what if I open a hole in the inside fenderwell... what do you think?

 

Both the rear exhaust manifold bolts were broken on my engine, flush with the gasket surface. When I had the heads off for a head gasket change, I had them removed and helicoiled. I think GM didn't allow for the expansion contraction of the manifold, and as they use a long bolt with a spacer, the bolt is forced back and forth until it snaps flush to the head. I used new bolts, undertightened, with never-seeze. I snug them every month or so.

 

Thats a possibilty you might try.

 

Are you serious?!?!?

Hell... if that's the case then that will be easy... WOW...

thank you

 

Sorry, I thought you meant the bolt for the y-pipe connections. You really should remove the head.

 

On the very front port and last port on the outside edges there is 2 bolt holes near the port the stock manifolds use the outside bolt hole and headers use the inside one closest to the port.
http://cgi.ebay.com/ebaymotors/ws/eB...tem=2419610283
here are some pics to get an idea

 

Thanks alot for all your help... you guys are great...

 

I had the same thing happen to me. I broke the bolt off in the very back of the drivers side head. I tried to drill and ez out it but broke the ez out off trying to remove it. I use a right angle drill and a mirror to see what i was doing. I wouldnt try to drill it. I didnt get into the threads but was very close. I ended up pulling the head and took it to a weld shop. They welded a stud to the ez out ant broken bolt and got them out. There was no damage to the head at all. I talked to the guy that fixed it for me and he said that he could have done it on the car if i hadnt tried to already drill it and ez out it. If it happend to me again I would take it to a welding shop and see if they can do it. If not make it an excuse to get your heads ported and install a cam like I did.

brad

 

It is pretty common for those last bolts to break. It doesnt seem to cause exhaust leaks, though. Usually people don't even know about the broken bolts until the go to do a header install. Headers generally use the other (unused) bolt hole.