Broken exhaust manifold bolt..need help!
 

I was taking off the stock exhaust manifold bolt and the bolt snapped in half. There is about 1 thread sticking out from the block itself. I can't get a pair of vice grips or anything on it b/c there is no room. Has anyone ever been in this situation, and what did you guys do..

Are you talking about the one that attaches to the block?

If you're talking about the actual manifold-to-block bolt, you need to remove it right as it is.

EZ Out. Also called a stud extractor. You have to drill a tiny hole in it as a pilot, and extractor digs into that hole to twist it out. If you don't have any liquid wrench or PB Blaster, you should buy some now and start soaking it.

Dave

ez out and if that doesn't work looks like a helia coil is in your future. Or a new rotor housing. Good luck you will need it.

i know your frustration and nervousness....the ez-out is a great tool to have....and PB blaster/Liquid wrench is a godsend...just don't get all worked up and try to rush the extraction....take your time.

God help this guy if he is trying to drill a hole for an EZ-OUT extractor with the engine in the car! :(

Further recommendation is to get a CARBIDE drill, most high-speed steel drills, even TIN coated ones, will not work well trying to drill these bolts that have been thru so many heat cycles.

Good luck with this....what a PITA to have to endure!

Use an angle electric drill with a new bit SIZED for the easy out you will use. Use the fluted ( not spiral type ) easy out. Drill the hole completely thru the broken stud - and centered. Now calculate where to stop drilling - don't drill thru the housing. Once the hole is drilled, PB blast right thru the hole to the back of the stud, and the threads in the back of it. Let soak. Now tap your easy out in Straight and true. Put moderate pressure on the easy out - do NOT snap it off or you are out of business. It will come out....with patience.

Tom

ok im going to try an easy out....last resort will be a hela coil. Theres no way im buying a new housing. It will come out!

well i have been drilling at the stud for about an hour now and it has barely starterd to dig in...right now im just venting because im so pissed that this had to happen to me. I would have never thought a broken stud would be in my block...well if anyone has anymore ideas ill be outside drilling a 5/32 drill bit into a bolt....leave me some love.


and yes it is a carbite bit...................................:Kill1:

damn, i know how you feel man. I had ran to similar problems like you. Took me two whole night. I ended up using a dremel and cut the turbo manifold to get to the stud and the stripped nut. Cause like what you say, there's no freaken ROOM to work at all. Anyways, you should of not use the drill, because it's not going to drill a hole, instead the stud is just going to expand wider as it gets hot from the drilling.

You should of went to the hardware and bought yourself a set of those "Stud Pullers" it's a socket that will grab onto the whole stud and all you got to do is twist the stud out.

STOP! Take a deep breath and leave the car alone. Walk away now.

Then when you are totally bored, calm etc, go back and try. Trust me, the LONGER you take doing this job, the quicker it will get done (if you catch my drift).

Actually, momentary heating from the drilling of the bolt is a GOOD thing, the expansion will help to break the bolt/stud loose. And once the hole is drilled, the bolt/stud will have a natural tendancy to shrink slightly, just a few tenths of a thousandth maybe but still some.
As for the 'stud puller', I think the original post said something about it being broken clean off, so there would have been nothing to grab onto(?).
Regarding drilling this stud. You need to use the proper drill and the proper rpm or all you will do is dull the drill. You need SLOW surface speed....slow rpm. Use a good lubricant or cutting oil if you have it. Tapping fluid would be best in fact.

I usually can't find cutting fluid - so check for plumbers pipe tapping oil instead.

Dave

Yeah, but it didn't work for me. That was what I was trying to get to when I was drilling, but it just made it worst. It generates heat and expand the stud, instead of drilling it a clean hole. On top of that it was taking too much time.

oh okay. I read it wrong then. I thought he say there's still some thread left. If all else fails... I say bust out that dremel.

how would i bust it out with a dremel???!?!

so basically carve out the stud that is in the block with a dremel...sounds risky...i was just going to trailer my car to a machine shop and have it done...they said they can have it done in an hour....lol

man this is depressing i was ready to install my 35r kit too :wallbash:

Done the same thing when I swapped out a pair of twins... took days to get the *&^&$^ thing out after buying a right angled drill (limited space to drill down there!)
helacoil didnt work either - had to retap the hole from 10mm to 12mm

i think im jsut going to trailer it to a shop and have them pull the broken stud out...They said they can have it done in 1 hour....i know it is the pussy way out but i dont have time to deal with this bullshit :)

Maybe you can pay them extra to make a house call so you don't have to trailer it. Getting it done right without breaking anything else is definitely not the pussy way out.

ty:jump: