Broken Manifold bolt.............. Suggestions...........

My friend and I were prepping my engine and installing a new oil pan.. he noticed the driver side rear manifold bolt was broken and there were signs that both sides had leaking manifold gaskets... luckily the rest of them came out with no issue... the one that is broken is broke off almost flush with the head.. Any suggestions on the easiest way to fix without removing the head and taking it to a machine shop...

Also should I go back with OEM bolts or something different... this seems to be a problem with the stock stuff... I will be re using my stock manifolds

Weld a nut to the stud. Since the head is aluminum it will not stick to head. Weld a little bump on stud hold nut up and weld center up. Then just remove it worked on 3 on my bolts.

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Originally Posted by 1991SSP

My friend and I were prepping my engine and installing a new oil pan.. he noticed the driver side rear manifold bolt was broken and there were signs that both sides had leaking manifold gaskets... luckily the rest of them came out with no issue... the one that is broken is broke off almost flush with the head.. Any suggestions on the easiest way to fix without removing the head and taking it to a machine shop...

Also should I go back with OEM bolts or something different... this seems to be a problem with the stock stuff... I will be re using my stock manifolds

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you can get stud extractors, where you drill a hole and use a left handed extractor to turn it back out too.

i tried this and the extractor broke so i had to take the head up to the shop and use a carbide endmill to clean all that shit out and re-tap it to clean the threads.

Done both ways. If you need more room, loosen body bolts, undo steerin shaft, and jack up the body a little bit. Makes easier when going through the fender. If you undo your grounds too, you could raise it up to 4".

Going to give the welding a nut to the stud a try in the next few days

Prior to doing anything shoot some penetrating spray in there and let it sit. I would suggest doing this a few times then letting it sit
Should make getting it out easier.

Man this crap sucks when it happens and very common it's either the front one or back one lol easier with engine or head off... I drill and re tap them with slot of wd40

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Originally Posted by LsSonoma

Weld a nut to the stud. Since the head is aluminum it will not stick to head. Weld a little bump on stud hold nut up and weld center up. Then just remove it worked on 3 on my bolts.

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Take inner fender out and do what he said, it will work an not that hard. If u don't have means to what u need talk to friends, no need to remove head, just more work, that is not needed. Hope everything goes well for u!

Copper rtv. That's what I did. Works great and no more leaks.

It isn't gonna come out too easy because those bolts have yellow locktite on from the factory so i doubt penetrating oil will do much but welding the nut on might be a good shot because it gives you something to turn it out with and may heat up the locktite enough to break it free.

I've been here to usually ill drill a center in the broken bolt then
Drill a hole just a hair bigger than the stud kinda cutting into the head,
But that second hole is just a hair like an 1/8 deep. Sthenuse a
Reverse drill bit... The second step help the resistance built from backing it
Out..... Trust me it comes out like butter...
We've gotten allot of oils well trucks from KEIWIT, and they
Always have broken studs all over the place because of the lignite rock
They are surrounded by.... It really fucks up metal...
Hope that helps

My iron headed 6.0 had all 4 corner bolts broken flush with the head. I drilled a small hole through the center of the bolt. I then used a torch and aimed the flame right into the hole for about 30-45 seconds. After it cooled slightly, I used an easy out. They all came right out. Hopefully yours won't give you much trouble.

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Originally Posted by kerrige

Prior to doing anything shoot some penetrating spray in there and let it sit. I would suggest doing this a few times then letting it sit
Should make getting it out easier.

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this

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Originally Posted by gta87305

It isn't gonna come out too easy because those bolts have yellow locktite on from the factory so i doubt penetrating oil will do much but welding the nut on might be a good shot because it gives you something to turn it out with and may heat up the locktite enough to break it free.

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i sprayed my 10yr old factory bolts with PB Blaster once a night for a week getting ready for my header install, and every one came right out with no problems. i even reused them all & they're still good now.