Hello guys, I'm in the process of installing 94-95 MAC headers into my 97 firebird, on the passenger side header the last bolt broke off and is stuck in the block, there is another hole next to it and I was thinking about drilling a new hole in the headers flange and the gasket, any one have any other ideas???? I'm worried I might not be able to drill through the header.

Also, the two nuts that hold the EGR tube on are stripped so I can't remove it I tried hooking it back up but I guess 97 and 94-95 EGR's are different. Any ideas on that.

 

You can probably get it out with one of those bolt removal kits and auto parts stores. You drill a hole in the broken off bolt and insert a tool in the bolt and it'll turn right out.

I dont think drilling a new hole is a good idea at all!

For the egr stripped nut.. if it's anything similar to what I have a 95 ta, you might could use stripped socket removers or heck a small vise grip. If all else fails, leave the tube on and block off the open end.

Sounds like trying to force to many things to work or using the wrong tool. Be careful and making things work will only take more time in long run.

 

Well I got the EGR tube off, THANK GOD, but anyways the only way I could get a drill to where the broken bolt is, is by pulling the head off, which I'm assuming isn't the most easiest thing to do. (If it is actully easy, and I'm missing something let me know.) I woundn'lt be drilling into the head I would only be drilling the MAC header flange, i could post a picture if anybody wants. Basically next to the broken bolt hole is another hole which a header bolt fits into perfectly.

 

the only other hole would be for a spark plug I thought...

 

Is the bolt broken off flush with the heads, if not can you get a stud puller down there to back that bolt out?

 

Actually there are two header bolts right in a row by the front and back primaries.
No the bolt is broken off deep into the head.


Basically what I'm wondering is if anybody sees any problems with me drilling a new hole in the header flange and gasket, there is plenty of room in the flange.

 

I ran into the same problem as you when installing my Mac's. The very back exhaust bolt broke off flush and I decided to do what you are thinking about. I just drilled a 3/8" hole in the header flange and the gasket. Everything turned out perfect and have had no problems with leaks.

 

Oh my god, this install is hell, I managed to drill a hole (a couple of holes actually and the back bolt now goes into the hole perfectly, but now for some reason one of the header bolt holes got stripped out, I know this isn't the correct thing to do but I think I'm just going to break out the torque wrench and force it in. This is really turning into a pain in the butt, oh yea, the new coolant temp sensor that I bought, for whatever reason it won't hook up to the old harness

 

when you were little and there were differnet shaped blocks with different shaped holes, did you have problems? he jk...

it sounds like youre not patient, and just trying to throw stuff together, clean up the bolts and threads, and make sure everything is going in strait.

 

let me guess, you got the autozone coolant sensor? Same thing happened to me.

 

Wow man. You sound EXACTLY like me. I have a 97. I bought mac mids for a 97. Last bolt broke off on PS. Second bolt from the front on PS side stripped out somehow. NO CLUE HOW. Drivers side took 20 minutes. Easy as hell. Like you, I drilled a hole in the header and gasket. Take the old gasket, there should be a mark on it showing where the hole is, so you have somewhere to mark it.

What I had to do to get that bolt in... It wouldn't even get started. So I took a bolt of that size, but with a point on the tip, so it wasn't flat. Forced that in to make new threads. Pulled it out, and the stock size bolt went in. Might have to keep tapping it though. Maybe use an extra washer like I did.

I have been running this way for a couple months, no leaks or anything. Sure beats pulling the heads.

Only thing that sucks about not getting that last bolt out is it's a PITA to wrench the bolt into the other hole cause it's so close to the primary. Good luck man.

 

Thats really wierd, basically the exact same problems, so what exactly did you do? Just take a header bolt and file it down to a point? I really don't want to have to remove the cylinder head. I bought a tap set but I have to use a drill with it and there is no way I could fit a drill in there.

 

Well I actually managed to get a bolt in there with a washer, now I just have to pray it's tight enough to not leak, and for whatever reason it seems everbody told me the dipstick would be a major PITA but it slipped right out and slipped right in for me. Go figure.