POLL: favorite method for removing busted exhaust manifold bolt - The 1947 - Present Chevrolet & GMC Truck Message Board Network

littlevictories · 02-05-2014, 03:23 AM

get out the vote!

A) try and weld a nut (it's under flush so this would be hard)

B) pull the head, use drill press and drill it out

C) free hand drill and use easy-out (this has cost me dearly before)

D) quit dickin around, pull the head, take to machine shop ($200 in labor and parts)

E) dump motor in CL seller's yard, maybe do some other landscaping too

ls1nova71 · 02-05-2014, 04:03 AM

The outer bolts seem to break off on engines when they get to around 100k, it's not an uncommon problem at all. I usually weld a nut on them. Even if it's a little below the surface, you can weld them since the weld won't stick to the aluminum. Just make sure they cool before trying to back them out after welding.

BR3W CITY · 02-05-2014, 04:05 AM

Which motor? stock heads on a truck motor, I'd just get a another set of heads and put them on, then take my old heads and have them ported (and that bolt taken out) while they are sitting on the bench, then throw the better set back on when its convenient.

**truckdude239** · 02-05-2014, 08:15 AM

Dorman now makes a clamp style thing that bolts to the back of the head and presses the manifold the block for the back bolts

littlevictories · 02-05-2014, 04:20 PM

I gave the weld method a shot and it worked.
Here's a link to the write-up I was pointed to on another board. http://ls1tech.com/forums/forced-ind...t-removal.html

farmtrucks · 02-05-2014, 09:16 PM

Weld method - takes about 1 minute per bolt, use a wrench and get it out as quickly as possible.

crazy longhorn · 02-05-2014, 09:48 PM

I did the drill & easy out, on 3 of mine....all were broken 1/8-3/16 below the surface? Flush to , a little stick out, I would have done the nut washer/weldem up trick

Longhorn

68basket · 02-05-2014, 10:52 PM

Quote:

Originally Posted by truckdude239

Dorman now makes a clamp style thing that bolts to the back of the head and presses the manifold the block for the back bolts

more info please. Do you have the dorman number?

littlevictories · 02-05-2014, 11:16 PM

Quote:

Originally Posted by crazy longhorn

I did the drill & easy out, on 3 of mine....all were broken 1/8-3/16 below the surface? Flush to , a little stick out, I would have done the nut washer/weldem up trick

Longhorn

Gotcha, and that's what I've done for years (with varying luck) until today.
Mine was also 1/8" below flush, if you look at the bolts thats where the threads start on the neck. I just built up a little nub with weld, pushing as much heat into the busted bolt itself as possible. Then I sat the nut over that nub and went back at it. Let it cool down for a few minutes (It was 28*F today) and gave it a squirt with PBB, backed right on out.
Just make sure not to use any sort of coated nut...or corroded ones...lots of both in my random hardware can.

BR3W CITY · 02-06-2014, 04:19 AM

Quote:

Originally Posted by 68basket

more info please. Do you have the dorman number?

http://www.dormanproducts.com/p-6600...Repair%20Clamp

chuckmc8 · 02-06-2014, 06:14 AM

I used the mig welder method- Mine was broken 1/4" below the head surface. Just place the nut over the broken bolt- set your welder pretty hot and tack the nut to the broken bolt. (The weld wont stick to the alum head) then put your 9/16" wrench on the donor welded nut and wiggle it back and forth gently and it will loosen up and spin right out. Like others have said, less than one minute procedure. The rear manifold bolt on driver's side seems to be the most common to pop off.

Wasted Income · 02-06-2014, 10:34 AM

Welded nuts on them many, many times. Works like a charm.

Wasted Income · 02-06-2014, 10:35 AM

Quote:

Originally Posted by BR3W CITY

http://www.dormanproducts.com/p-6600...Repair%20Clamp

Wow...what a half-assed way to "fix" a broken bolt.

BR3W CITY · 02-06-2014, 06:50 PM

Never tried it, I had to google it, so I posted the number lol.

I can't wait to start seeing engines in 'yards with these lol

softballnrd27 · 02-06-2014, 06:56 PM

buy new heads

**truckdude239** · 02-06-2014, 08:52 PM

http://www.youtube.com/watch?v=dzM1E9vf5G4#t=94

crazy longhorn · 02-06-2014, 09:39 PM

Quote:

Originally Posted by Wasted Income

Wow...what a half-assed way to "fix" a broken bolt.

Yes that does look to be a half-vast way to fit a simple problem? longhorn

crazy longhorn · 02-06-2014, 09:40 PM

Quote:

Originally Posted by Wasted Income

Wow...what a half-assed way to "fix" a broken bolt.

Yes that does look to be a half-vast way to fix a simple problem? longhorn

littlevictories · 02-06-2014, 10:04 PM

eh, looks like a good way to put it off for later
signed
-a fan of the red green show

Andy4639 · 02-07-2014, 01:09 AM

I had one just today I had to weld another bolt to the head of the old bolt. It had rounded off. Welded a short bolt to it and it came right out.

**truckdude239** · 02-07-2014, 09:55 AM

Quote:

Originally Posted by crazy longhorn

Yes that does look to be a half-vast way to fix a simple problem? longhorn

yeah i've never used one i had a customer want me to install one and i said no i send him down the steeet to another shop and they welded a nut on it and it came right out

JMac11 · 02-07-2014, 10:10 AM

If you choose to drill, invest in left handed drill bits. The vibration, heat and the reverse rotation, I have seen them back right out in these situations.

02-05-2014, 03:23 AM	#1
littlevictories Registered User Join Date: Dec 2013 Location: Portland, Ore. Posts: 348	POLL: favorite method for removing busted exhaust manifold bolt get out the vote! A) try and weld a nut (it's under flush so this would be hard) B) pull the head, use drill press and drill it out C) free hand drill and use easy-out (this has cost me dearly before) D) quit dickin around, pull the head, take to machine shop ($200 in labor and parts) E) dump motor in CL seller's yard, maybe do some other landscaping too

02-05-2014, 04:03 AM	#2
ls1nova71 Registered User Join Date: Dec 2009 Location: Independence Mo Posts: 4,119	Re: POLL: favorite method for removing busted exhaust manifold bolt The outer bolts seem to break off on engines when they get to around 100k, it's not an uncommon problem at all. I usually weld a nut on them. Even if it's a little below the surface, you can weld them since the weld won't stick to the aluminum. Just make sure they cool before trying to back them out after welding. __________________ My '72 short bed build. http://www.ls1tech.com/forums/conver...6-0-4l80e.html 5.3 swap into my RUSTY '71 C10 http://ls1tech.com/forums/conversion...71-c-10-a.html

02-05-2014, 04:05 AM	#3
BR3W CITY meowMEOWmeowMEOW Join Date: Sep 2009 Location: MKE WI Posts: 7,128	Re: POLL: favorite method for removing busted exhaust manifold bolt Which motor? stock heads on a truck motor, I'd just get a another set of heads and put them on, then take my old heads and have them ported (and that bolt taken out) while they are sitting on the bench, then throw the better set back on when its convenient. __________________ *'66 Short Step / SD Tuned / Big Cam LQ4 / Backhalfed /Built 4l80e / #REBUILDEVERYTHING* MY BUILD THE H8RDCPTR //\\ MY YOUTUBE CHANNEL REV J HD

02-05-2014, 08:15 AM	#4
truckdude239 Senior Member Join Date: Sep 2005 Location: Lewisville, Nc Posts: 10,237	Re: POLL: favorite method for removing busted exhaust manifold bolt Dorman now makes a clamp style thing that bolts to the back of the head and presses the manifold the block for the back bolts __________________ David fuller Ase Certified Mechanic Click here to help support our board!! 1971 Chevy c-10 under going a 4.8l LSx swap Build Thread http://67-72chevytrucks.com/vboard/s...d.php?t=421305 2007 Honda Accord my daily 145kmiles 2002 Honda Accord 4 door With 330k(sisters car) 2005 toyota Avalon 228k( brothers car) 2002 Sububran 5.3 245k 2000 Tahoe 5.3l 378 General manager for Marco's Carwash & lube

02-05-2014, 04:20 PM	#5
littlevictories Registered User Join Date: Dec 2013 Location: Portland, Ore. Posts: 348	Re: POLL: favorite method for removing busted exhaust manifold bolt I gave the weld method a shot and it worked. Here's a link to the write-up I was pointed to on another board. http://ls1tech.com/forums/forced-ind...t-removal.html

02-05-2014, 09:16 PM	#6
farmtrucks Registered User Join Date: Jun 2011 Location: Sneedville, TN Posts: 831	Re: POLL: favorite method for removing busted exhaust manifold bolt Weld method - takes about 1 minute per bolt, use a wrench and get it out as quickly as possible. __________________ High School Project I ---http://67-72chevytrucks.com/vboard/s...d.php?t=639174 High School Project II ---http://67-72chevytrucks.com/vboard/s...27#post7290427 High School Project III ---http://67-72chevytrucks.com/vboard/s...d.php?t=715832 High School Project IV (Tyler) ---http://67-72chevytrucks.com/vboard/s...d.php?t=780186

02-05-2014, 09:48 PM	#7
crazy longhorn Fabricate till you "puke" Join Date: Jun 2002 Location: Ill Posts: 9,402	Re: POLL: favorite method for removing busted exhaust manifold bolt I did the drill & easy out, on 3 of mine....all were broken 1/8-3/16 below the surface? Flush to , a little stick out, I would have done the nut washer/weldem up trick Longhorn __________________ 69 longhorn,4" chop,3/5 drop, 1/2 ton suspension/disc brakes,1 1/2" body drop,steel tilt clip, 5.3/Edelbrock rpm intake/600 carb, Hooker streetrod shorties,2 1/2" exhaust/ H pipe/50's Flows , 6 spd Richmond trans,12 bolt/ 3.40 gears....

02-06-2014, 06:14 AM	#11
chuckmc8 It's alsways something..... Join Date: Nov 2008 Location: Douglasville GA Posts: 1,171	Re: POLL: favorite method for removing busted exhaust manifold bolt I used the mig welder method- Mine was broken 1/4" below the head surface. Just place the nut over the broken bolt- set your welder pretty hot and tack the nut to the broken bolt. (The weld wont stick to the alum head) then put your 9/16" wrench on the donor welded nut and wiggle it back and forth gently and it will loosen up and spin right out. Like others have said, less than one minute procedure. The rear manifold bolt on driver's side seems to be the most common to pop off. __________________ 1968 RS Camaro 'Vert Matching number 327 and M21 Muncie 1968 C10 Black with red interior and orig paint. 5.3 / 4l60e,3:73 POSI 17" Torq Thrusts 1968 CST 514 Red with black interior. Buddy Buckets, Factory A/C, PS, PB- 20" AR custom shop TT, 5.3 and 4l60e

02-06-2014, 10:34 AM	#12
Wasted Income Boosted Member Join Date: May 2002 Location: Mackinaw, IL Posts: 2,200	Re: POLL: favorite method for removing busted exhaust manifold bolt Welded nuts on them many, many times. Works like a charm. __________________ 1972 2wd K/5 Blazer Turbocharged 370 LSx - 941 rwhp / 1093 rwtq 1969 Chevy K-10 L33 5.3 / 4L80E / NP241 / 4" lift 1964 Buick Skylark Twin TURBO 383 LS pro-touring project 2014 VW Passat TDI - Daily Driver Turbo diesel 2015 Sierra Denali HD Duramax Turbo diesel 2023 Ford Explorer ST - Twin Turbskis 2023 Ford F150 RCSB - Whipple Supercharged 2017 Polaris RZR Turbo 2014 Nor-Tech Center Console - Twin Supercharged Outboards *TURBO ALL THE THINGS!!*

02-06-2014, 06:50 PM	#14
BR3W CITY meowMEOWmeowMEOW Join Date: Sep 2009 Location: MKE WI Posts: 7,128	Re: POLL: favorite method for removing busted exhaust manifold bolt Never tried it, I had to google it, so I posted the number lol. I can't wait to start seeing engines in 'yards with these lol __________________ *'66 Short Step / SD Tuned / Big Cam LQ4 / Backhalfed /Built 4l80e / #REBUILDEVERYTHING* MY BUILD THE H8RDCPTR //\\ MY YOUTUBE CHANNEL REV J HD

02-06-2014, 06:56 PM	#15
softballnrd27 Always a work in progress Join Date: Jun 2007 Location: Harker Heights, TX Posts: 1,599	Re: POLL: favorite method for removing busted exhaust manifold bolt buy new heads __________________ USMC Retired Never trust a man who can't laugh at his own fart! 2010 Silverado Crew Cab 73 SWB 5.3/4l80e Build Thread: http://67-72chevytrucks.com/vboard/s...d.php?t=695168

02-06-2014, 08:52 PM	#16
truckdude239 Senior Member Join Date: Sep 2005 Location: Lewisville, Nc Posts: 10,237	Re: POLL: favorite method for removing busted exhaust manifold bolt http://www.youtube.com/watch?v=dzM1E9vf5G4#t=94 __________________ David fuller Ase Certified Mechanic Click here to help support our board!! 1971 Chevy c-10 under going a 4.8l LSx swap Build Thread http://67-72chevytrucks.com/vboard/s...d.php?t=421305 2007 Honda Accord my daily 145kmiles 2002 Honda Accord 4 door With 330k(sisters car) 2005 toyota Avalon 228k( brothers car) 2002 Sububran 5.3 245k 2000 Tahoe 5.3l 378 General manager for Marco's Carwash & lube

02-06-2014, 10:04 PM	#19
littlevictories Registered User Join Date: Dec 2013 Location: Portland, Ore. Posts: 348	Re: POLL: favorite method for removing busted exhaust manifold bolt eh, looks like a good way to put it off for later signed -a fan of the red green show

02-07-2014, 01:09 AM	#20
Andy4639 Old member Join Date: Jan 2002 Location: Liberty, & Garden City S.C. , U.S. Posts: 19,945	Re: POLL: favorite method for removing busted exhaust manifold bolt I had one just today I had to weld another bolt to the head of the old bolt. It had rounded off. Welded a short bolt to it and it came right out. __________________ 1971 LWB Custom, 6.0LS & 4L80E, Speedhut.com GPS speedometer & gauges with A/C. 20" Boss 338's Grey wheels 4 wheel disc brakes. My Driver Seeing the USA in a 71 Upstate SC GM Truck Club 2013,14 and 2016 Hot Rod Pour Tour http://upstategmtrucks.com/ Get out and drive the truck this summer and have some fun! It sucks not being able to hear! LWB trucks rule, if you don't think so measure your SWB! After talking to tech support at Air Lift I have found out that the kit I need is 60811. Per the measurements I gave them. Ride height of truck inside spring and inside diameter of springs.

02-07-2014, 10:10 AM	#22
JMac11 Registered User Join Date: May 2005 Location: Tallahassee Fl Posts: 773	Re: POLL: favorite method for removing busted exhaust manifold bolt If you choose to drill, invest in left handed drill bits. The vibration, heat and the reverse rotation, I have seen them back right out in these situations.



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