Dorman exhaust manifold mounting hardware is designed to replace broken, stripped, or corroded stock fasteners. But the one problem would be to get the nuts broke loose without breaking the nuts off. Details about KAP169 - Exhaust Manifold Bolt Repair Kit - No Need to Remove Broken Bolts New E BOXSTER/996/997 EXHAUST BOLT REPAIR KIT (SR067) Details about KAP169. org forum who had the same problem, they welded a new nut to the sheared of bolt then used a socket to remove them. Average repair cost is $720 at 74,450 miles. Remove the bolts that hold the exhaust manifold to the catalytic converter or exhaust pipe. Remove exhaust manifold bolts on cylinder 7. Often they are fine, but replacement is far easier with the intake off. Manifold bolts break all the time!!! This is very common on all vehicles. 4 exhaust manifold cab on removal 6. Broken Manifold Bolt repairs are never fun to deal with, but Beydler’s Manibolt Driller® is the best possible solution to a worst case nightmare. Your mechanic may charge you an additional fee, depending on the severity of the situation. The previous owner broke one bolt head on the exhaust manifold. In most cases, attempting to remove the bolt stem with locking pliers does little. 4 days in the shop. Any tips on how to remove this thing? I have heard to use a carbide bit or a diamond bit. Anyone had any luck removing a broken stud on the exhaust flange? Yes a couple of times, With exhaust pipe out of the way, from the broken side of stud put a round chisel or like tool and then pound the stud out of the flange, it is pressed in. Provided you can get the manifold off, removing the broken bolts should be easy enough with a good quality (ie not Chinese) self grip wrench. I have two bolts that have broken off in my exhaust manifold on each of my heads. But, the item was in a vise on the work bench where I used new set of Vise Grips and alternated between heat and penetrating oil. This would be a big mstake, because it puts some of the mounting bolts into a bind and that can lead to broken mounting bolts. Broken Manifold Bolt repairs are never fun to deal with, but Beydler’s Manibolt Driller® is the best possible solution to a worst case nightmare. It may be wise to buy new exhaust manifold "donut" gaskets as well. I remove the head if I have broken studs below the surface of the head. Exhaust piping can break for a number of reasons. If the bolt needs to be drilled out you can use our insert to repair it and restore it back to the size it was to begin with. 3 (Below) Remove the nine 12mm nuts. It is not noisy/leaking at this time. If your exhaust manifold needs replacement, you're in for a hard procedure. They are likely to break. The balance of the exhaust system stays in place. This head is identical to the 318A, and has all of the same Magnum features such as the ten-bolt valve cover rail and Magnum valvetrain, but is machined with the LA series intake manifold bolt. Details about KAP169 - Exhaust Manifold Bolt Repair Kit - No Need to Remove Broken Bolts New E BOXSTER/996/997 EXHAUST BOLT REPAIR KIT (SR067) Details about KAP169. Run the engine and make sure there are no exhaust leaks. Plan to replace any exhaust hardware that you remove. does anyone know of a place where I can order a set of brand new exhaust manifold to head bolts? Fomoco wants $17 per bolt and I don't really feel like putting out over $200 just for bolts, so I'm hoping they aren't the only ones who can get ahold of em. How much should it cost to fix ? I have a 1998 Jeep Grand Cherokee. Took it in for it's oil change (religiously done every 3,000 miles since I bought it 145,000 miles ago) and mentioned to the service manager "Look for an exhaust leak. That stud was probably weak since it snapped pretty easily (I dont weigh anything). For the CH150 muffler, the 10mm nuts are circled in green and the 12mm bolts are circled in red (the two green circles on the top right are for the exhaust manifold nuts. make model engine. One (1) where the exhaust collector meets the exhaust pipe that goes to the muffler, just before the crossover pipe. I have also heard about taking the manifold in to have "spark erosion" used. … oem Exhaust Manifold Repair Kit LH & … When to Get Exhaust Manifold Repair. I have noticed that it looks like it is the original gasket. It cost me about $750 for parts and labor. The exhaust manifolds on your Ford vehicle routs exhaust gases into the exhaust system. Exhaust manifold bolts on 2002 Chevrolet 2500 hd 6. The bolt snapped off flush with the mating surface of the exhaust port, leaving only about 3/16" of the bolt sticking out the back side of the exhaust port "ear". I removed the broken stud by welding on a stainless steel nut 3/8 just so I didn't have to deal with the plating. Exhaust Manifold Bolt Removal. Follow these steps to fix broken manifold bolts. 6 hours plus bench time to drill out the broken studs @ 85. And I've seen quite a few broken EZ-Outs over the years, and they create a real mess. Am I asking for trouble to remove the manifolds and try to remove the broken bolt?. if the engine is a 2,4 liter, and if your replaceing the manifold gaskets, the manifold has 8 13mm bolts you need to remove, and also you need to drop the pipe, remove the 3 13mm bolts that. You should look at the part of the manifold closest to the heater box real close and make sure it's not cracked, and no bolt heads are broken off. Now, a new kit part, number TS11209, is available exclusivley through Cad Company for all '68-'85 Cadillac 472, 500, 425, and 368 engines. /70,000 emissions warranty. Ford quoted me about $1200 to fix it because they have to pull the cab. i bought a set of pacesetter headers for my 96 4. Once its warm take an old candle and push it against every nut/bolt. Broken exhaust manifold bolts can be extremely stubborn to remove, and risk of breaking an EZ-Out is high. They ended up breaking two more bolts off in the head and werent able to get one out when trying to replace the manifold. That KAP bolt repair kit looks like the way to go. They are going to replace it with a new Dorman manifold, gasket, and bolts for $410. Most mechanics cringe at the thought of removing broken exhaust manifold bolts as sometimes the engine will need to be removed in order to drill the bolts out. With more and more broken exhaust bolts reported on the water-cooled engines, the headache of repairing a broken bolt is becoming epidemic. 00 for the set. Lower intake manifold bolt tightening sequence-4. Dealers are to replace the exhaust manifold if it is determined to be cracked. make sure the new bolt have anti seize on them, take you time its a easy install. Right now it has the ticking from the leak until it warms up. Remove the bolts that hold the exhaust manifold to the catalytic converter or exhaust pipe. Labor, depending on your location, will cost anywhere from $45 an hour to $70 an hour. For the past 2 weeks, I've been trying to remove the nuts that connect the Y-Pipe and the exhaust manifold. Then, remove the exhaust pipe from the manifold. I replaced the bolts on the driver side, except for the back one that is sheared off flush with the cylinder head. Removing exhaust bolts is often a lengthy, difficult and frustrating task for auto mechanics. He said they - those bolts in the 6. Makes a really bad tick. It is leaking a little at the exhaust manifold so it is time to replace the gasket. The process requires the removal of tons of components, but you will end up saving some serious money. Is a Cracked Exhaust Manifold Dangerous? Although a cracked exhaust manifold does not directly cause danger, it can indirectly be dangerous, as the issues it causes makes a car unfit to drive. In this video we go over another popular technique to removed stuck broken bolts and studs using welding. That one is in the exhaust manifold and MOST IMPOSSIBLE to remove. During valve overlap, when both the exhaust and intake valves are open at the same time, it is possible for these particles to get sucked back into the cylinder. To do this I cut the nut/bolts with an angle grinder, which left two useless stubs of a rusted bolts in the "Y" section. Cost to replace 2 Exhaust manifold studs $600+!!?? Talked to my Volvo guy today from European Auto in Modesto, I really trust these guys but I was quoted a hell of a lot, they said they have to pull the manifold and redrill, they can progably do it without pulling the head, it's going to cost about $600-$650 plus $70 per additional stud that. I believe this is a 8mm bolt some places can weld a nut on the end and remove the bolt. So after, I hit each of the rest with a propane torch and applied PB Blaster and the rest gave right up. Exhaust Manifold Bolt Repair Kit. Those trucks have a history of broken bolts and cracked manifolds. The same bolt broke off on the driver side. So I had to chisel, cut, and grind off the bolts (or studs?) holding that y-pipe onto the manifold. The exhaust manifold bolt closest to the firewall is broken off my Rebel 232. "I wanted to inform you of the repair cost savings using your tooling. Broken exhaust manifold bolt. An example of the perils of alloy steel bolts is the 12mm exhaust manifold bolt my friend Brian broke off in the head of his 12V while trying to remove it with a 3/8" drive ratchet, or the 2 12mm turbo mount studs I broke off (and had to extract by TIG welding a nut to them) with a regular box end wrench. For the CH150 muffler, the 10mm nuts are circled in green and the 12mm bolts are circled in red (the two green circles on the top right are for the exhaust manifold nuts. -Hammer smaller socket onto nut-Torched it-Hammer the nut itself-Sprayed WD-40 and let it sit for days-Using Irwin stripped nut removal. Once I get the bolts and manifold out should I try to vice grip the broken bolt out?. If the nuts happen to break then it would have to be drilled out, and retapped. If you get your existing manifold machined flat and DIY the job then obviously that will be a lot cheaper. The objective of the Exhaust Manifold Bolt Repair Bracket is to stop exhaust leaks that occur between the exhaust manifold and the cylinder head on 1999 and newer model. 00 dollars per hour. Didn't want to get into removing manifold,motor runs to good to take a chance breaking any more bolts removing manifolds then having to pull heads. High quality online resources for Ford Exhaust Manifold Bolt Recall. Exhaust Removal 3. Manifold bolts break all the time!!! This is very common on all vehicles. Broken bolts on exhaust manifolds is not a new problem. The side I watched get repaired was the drivers, they put the truck up on a lift, removed the front wheel and removed the wheel well liner, all of the bolts, got the manifold out of the way, removed the broken studs, reinstalled new studs, new gasket and reassembly. Using the Manibolt Driller you can drill directly into the center of the broken bolt or stud instead of drilling off center or at an angle. If you get your existing manifold machined flat and DIY the job then obviously that will be a lot cheaper. Otherwise, expensive bolt extraction and thread repair may be needed. The dealer wanted to install a new head, the warranty folks want to remove the head and send it to a machine shop to extract the bolt, which we will go with. At first I was set on fixing it but I remember the last time I had the exhaust manifold off a few of the other studs broke and it turned into a major PITA to get everything back together. I had the dreaded leaking exhaust manifolds that so many of us have and found that on my drivers side manifold there were 2 broken bolts flush with the head, the front and rear. That one is in the exhaust manifold and MOST IMPOSSIBLE to remove. On some one-piece exhaust systems, there are often leaks at the joint with the manifold. Seams like these are the most typical and also hardest to remove. This is a quick and totally accurate tool to repair and replace broken studs without damaging the head, or worse, having to remove the engine. exhaust manifold collector studs removal. Jeep Grand Cherokee 1993-2004: The Ultimate Exhaust Guide. "We have seen extremely high demand for the ISX kit among fleet companies. Background: I used my new air impact wrench (IR 236) and bolt extractor set to remove a rounded off exhaust flange nut/bolt from the front down pipe. Commonly found in fleet trucks and heavy equipment, the Cummins ISX engine demands a specialized kit to address its unique characteristics and exhaust manifold maintenance procedures, according to the company. Exhaust Removal 3. For all other cylinders, only replace studs that are broken or that may have backed out during exhaust manifold removal. Dodge Ram 2009-Present: Exhaust Manifold Bolt Issue. If you can't getthe casting too hot, you can actually spray cold water on the hot bolt to shrink it to break the rust loose. After getting all the exhaust manifold nuts off, I only counted 9 of them. The same thing happened on my 04 Trailblazer. On top of that, that is impossible on the LS1 as it has a dry intake manifold. Remove the bolts that hold the exhaust manifold to the catalytic converter or exhaust pipe. Broken Exhaust Manifold Stud(s) 2004 F250 4x4 XLT Sport Crew Cab. So I decided to remove the whole lot from the heads. Years ago when I worked for dealerships there was a company in town that specialized in broken bolt extractions. I just had my exhaust manifold replaced. Well the rear most bolt is somehow broken off flush with the head and the shop wants to remove the enitre head to get this out, which will cost me roughly $900. High quality online resources for Ford Exhaust Manifold Bolt Recall. Trying to get into there and drill out the bolts to use an EZ-Out looks like a real nightmare. Cost to repair broken manifold bolts. Exhaust Manifold Bolt Repair Kit. Broken exh. This makes it tough and you may find that it helps to hammer a smaller size metric socket on the heads to get them out. That stud was probably weak since it snapped pretty easily (I dont weigh anything). 2 (Below) Remove the 12mm pipe to manifold bolts. Manifolds First off if your doing a 6. Currently, I have got one used exhaust manifold to replace the cracked one. If the car will startwarm the engine and exhaust. Take off the manifold and renew the gasket. Home » ATHS Discussion Forums » Tech Questions and Tips » Broken exhaust manifold bolts Broken exhaust manifold bolts Posted By Tinyshaker Wednesday, October 21, 2009 3:34 AM. … oem Exhaust Manifold Repair Kit LH & … When to Get Exhaust Manifold Repair. Average labor rate around here (near Pittsburgh) is about 300. Am I asking for trouble to remove the manifolds and try to remove the broken bolt?. Two garages that I have visited do not want to touch it and the Ford dealership has provided an estimate of between $1,800 - $4,000. 0 l v8 are broken at the back bolt on the drivers side. Maybe they gave you that price so they wouldn't get the job. 4L Ford Extract Worn or Broken Bolt Studs. By For example, exhaust manifold studs are notorious for corroding the shanks thin as twigs and just as easy to break. How To - Replacing Your Cars Exhaust System Cat To Muffler Automotive In the shop today is a 1990 Honda CRX and we will be replacing its original 21 year old exhaust system. American Fanatics R7800 used parts + labour. Remove Exhaust manifold as described in the R33 Workshop Manual on pages 135 / 6. 4 days in the shop. 4L … Jul 11, 2013 · How to remove an exhaust manifold from a 2000 F150 5. He said he's ran into that alot and that they break flush with the head so you have to remove the head because there's not enough clearance between the head and the. These particular bolt materials are too soft and will not hold the necessary torque setting, which can cause leaks at the gasket surface. With the alum. Broken Manifold Bolt repairs are never fun to deal with, but Beydler's Manibolt Driller® is the best possible solution to a worst case nightmare. The exhaust manifold was too warped to reuse. The Studfix clamp is and easy to install clamp that is a great alternative to replacing rusted or broken exhaust studs. The bolts come up from the bottom and the nuts are screwed onto 2 studs secured into the cat flange from the top. In the end, 5 more exhaust manifold bolts broke off during removal. To make a long story of removing the manifold short, the anti-seize bolt at the rear of the engine had sheared and looked like it had been that way for a long, long. 2L engines. Broken exhaust manifolds bolts have become a common problem on 4th generation Dodge Rams. I used a Sawz-All (reciprocating saw) on the upper bolt and a Dremel cutting wheel on the lower one. 0, in the precess of trying to remove the stock manifolds, i rounded off about 6 heads on the manifold bolts. So what are my options. Cost: INTAKE MANIFOLD $1,348. I soaked them daily for a week with penetrating oil, and then dropped it off at a trusted mechanic. The best way I have found to remove a flush-broken bolt is to weld it out. If you have a BEW pumpe duse engine, also see 1000q: BEW intake manifold removal. This makes bolt removal 100 times easier for the next person taking it apart!. * Then remove exhaust manifold bolts. Find Dorman Exhaust Manifold Clamps 917-107 and get Free Shipping on Orders Over $99 at Summit Racing! Exhaust leaks and broken manifold bolts—Dorman has a solution: new exhaust manifold clamps! Their innovative repair clamps attach to the cylinder head, apply pressure to the manifold, and create a seal to take the place of the broken bolts. This problem is very common on the 5. Once the exhaust has cooled down try wrenching them loose. With more and more broken exhaust bolts reported on the water-cooled engines, the headache of repairing a broken bolt is becoming epidemic. I put 2 gaskets in to help hold the leak back a little better. Cost to replace 2 Exhaust manifold studs $600+!!?? Talked to my Volvo guy today from European Auto in Modesto, I really trust these guys but I was quoted a hell of a lot, they said they have to pull the manifold and redrill, they can progably do it without pulling the head, it's going to cost about $600-$650 plus $70 per additional stud that. Details about KAP169 - Exhaust Manifold Bolt Repair Kit - No Need to Remove Broken Bolts New E BOXSTER/996/997 EXHAUST BOLT REPAIR KIT (SR067) Details about KAP169. I thought that an ounce of prevention may be worth a pound of cure. throughout the process to keep them up to date on issues and costs. Plus, it’s cost-effective. Slip the exhaust manifold and gasket into position against the engine and replace the 12 manifold mounting bolts. A 2 piece manifold came off. I had a horrible exhaust leak that was caused by some backyard mechanic, no not mechanic, only an idiot would replace abroken head bolt with a drilled through hole an use a common bolt, nut and washer, in addition to using common SAE bolts to " secure" the manifold. How to Easily Remove a Cylinder Head on an Auto With Frozen Bolts. Be used to repair the Driver's Side Rear or the Passenger Side Front broken exhaust manifold bolts. Updated 02/09/10 -- Well, it looks like headers for me. Broken bolts are not uncommon when working on older engines like the Ford 390. With out even looking the guy said "its probably the exhaust manifold bolts. 2 if it goes badly broken bolts. After getting all the exhaust manifold nuts off, I only counted 9 of them. To remove the heat shield in most cases, you'll need to unscrew two to four bolts that are on top or to the side of the exhaust manifold. Exhaust Removal 3. Re: Ford 460 exhaust Manifolds: old timer: 10-8-11 : Ford E350 with 460, broken exhaust bolt on rear of engine. Makes a really bad tick. costs more but works better IME. The design of the manifold and the seal provided by the gasket assist in exhaust scavenging, where gas exiting from the cylinder leaves a vacuum which pulls in more of the air/gas mixture. During valve overlap, when both the exhaust and intake valves are open at the same time, it is possible for these particles to get sucked back into the cylinder. Generally, this condition is first noticed because of excessive exhaust noise that is the result of a manifold leak. The other s1de, about 1/2 hr, sprayed some silicone the Y pipe to make it easier. Is a Cracked Exhaust Manifold Dangerous? Although a cracked exhaust manifold does not directly cause danger, it can indirectly be dangerous, as the issues it causes makes a car unfit to drive. Labor costs are estimated between $483 and $611 while parts are priced at $1787. 8L gas engines. You remove 6 bolts per manifold that attach them to the engine, and 2 bolts per manifold that attach them to the crossover pipe. I can't say I blame you avoiding it, I've managed to snap 7 exhaust manifold bolts on my engine, all 6 of the passenger side cylinder head. Not cheap but a massive improvement. the template mounted up very fast, which I knew was going to be the easy part. Exhaust hangers support the exhaust system and keep it from contacting other parts. If it's just one problem bolt, it's possible to take the pipe loose from the manifold, take the rest of the bolts out, then twist the whole manifold a bit counterclockwise. My car has an automatic transmission. Average labor rate around here (near Pittsburgh) is about 300. I drove it to my mechanic and he has decided that some of the exhaust manifold bolts have broken. The good news is that the parts (exhaust manifold gasket and 8 bolts) only cost me $24 from the dealer with wholesale discount. Just unbolt them. Your Dodge Ram 1500 Exhaust Manifold collects exhaust gases from the engine and removes them using the vehicle's exhaust pipe. With more and more broken exhaust bolts reported on the water-cooled engines, the headache of repairing a broken bolt is becoming epidemic. The Fiero 2. I have a small exhaust leak that quiets down when hot. By continuing to use this site you consent to the use of cookies on your device as described in our cookie policy unless you have disabled them. It is not noisy/leaking at this time. Tighten intake manifold bolts first pass in sequence to 44 inch lbs. 00 to fix ill live with my 30 second exhaust leak. Cylinder heads are aluminum and there were no helicoil inserts in either one. The exhaust manifold bolt closest to the firewall is broken off my Rebel 232. Plan to replace any exhaust hardware that you remove. Well with labor plus part about 250 to 300. If the area is near the cylinder head, the head will take the heat and not do much to loosen the casting around the bolt. replacement stud will be a bolt and locknut. Soak the bolts in. I looked into the clamps, but for the cost of getting all four corners, I decided it was worth the effort to get them out. The Cummins ISX engine demands a specialized kit to address its unique characteristics and exhaust manifold maintenance procedures. I remove the head if I have broken studs below the surface of the head. I believe this is a 8mm bolt some places can weld a nut on the end and remove the bolt. 000km on the odo. Broken exhaust manifold bolt. During valve overlap, when both the exhaust and intake valves are open at the same time, it is possible for these particles to get sucked back into the cylinder. DIY - Snapped exhaust manifold stud removal Here is a little write up on how to remove the ever-so-common broken exhaust manifold stud, but can be used to get out other broken bolts. He said that this was a common problem and that they would remove the manifold, get the broken bolt out and replace all the bolts with new ones. Removing Broken Studs with a Torch. * Then remove exhaust manifold bolts. Dozens of options are available; choose the lengths and thread sizes needed for your specific vehicle application. Dodge Ram 2009-Present: Exhaust Manifold Bolt Issue. This is a discussion on Broken exhaust manifold bolt within the External Engine forums, part of the LSx Technical Help Section category; Damit! ! Every thing was going so well all the bolts were coming out no. Now, a new kit part, number TS11209, is available exclusivley through Cad Company for all '68-'85 Cadillac 472, 500, 425, and 368 engines. Run the engine and make sure there are no exhaust leaks. The Studfix clamp is and easy to install clamp that is a great alternative to replacing rusted or broken exhaust studs. Rust and corrosion can also fuse the exhaust manifold studs to the engine block of your older vehicle. I have already snapped one when penetrating lube did not do the trick, so I dont want that number to grow. Any thread would do as long as you have a new "bit of circular rod with sufficient thread" (technical term) exposed to clear the manifold flange. The manifold is attached to the cylinder head, and the unit is sealed with the use of a exhaust manifold gasket. Broken Exhaust Manifold Stud(s) 2004 F250 4x4 XLT Sport Crew Cab. Quick question for the people that installed aftermarket headers on their Tundra's. If you took out the oxygen sensors from the exhaust then leave them connected and set them aside. Sometimes an exhaust manifold starts to leak because a mounting bolt has broken. If there is a heat shield fitted, remove it. Your engine should sound and drive better (much better in my case). Noticed 3 broken exhaust manifold studs the other day on my 3406B Cat. Kral Auto Parts Store (507) 354-1945. Rust and corrosion can also fuse the exhaust manifold studs to the engine block of your older vehicle. 4L VIN L engines. I broke down and took it to Ford this afternoon and it turns out to be from a leak on the manifold from a broken bolt. Mechanic broke a bolt removing it on my work truck to replace the manifold. make sure the new bolt have anti seize on them, take you time its a easy install. When it came time to removing the exhaust pipes from the exhuast manifold I ran in to a big problem. @mjhicks you lucky SOB yours doesnt even requires removal of the manifold, weld a 3/8" short bolt to it and use a 9/16" socket to remove it, if you dont have a welder dont make it any more complicated stop by a mechanic shop they'll weld one on for you for 10 bucks, 1000x easier than mine 3 of which broke inside the head the manifold has to come out and extract/drill those out anticipating. That KAP bolt repair kit looks like the way to go. Broken Bolt announces the official release of its custom ISX broken bolt removal kit. Another said 6-8 hrs to repair because the head has to be removed. Note: To replace an exhaust manifold gasket, you will need to remove the exhaust manifold first. throughout the process to keep them up to date on issues and costs. The truck has 41,000 miles. is there a trick to removing old rusted exhaust manifold studs? the ones that attach to the exhaust pipe. My car has an automatic transmission. My 09 Saab 97X has the cracked manifold. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after July 26, 2011, are covered by this special coverage and must be submitted using the labor operation codes. Right now it has the ticking from the leak until it warms up. Labor costs are estimated between $262 and $332 while parts are priced between $718 and $760. Loss of horsepower and torque due to leaky gaskets is no way to enjoy your Truck. Getting Broken Bolts Out A broken bolt or screw is the bane of auto restorers, not to mention anyone else trying to fix any piece of machinery. The 2009 Dodge Ram 1500 has 13 problems reported for broken exhaust manifold bolt. Replacing exhaust manifold to cylinder head repair clamps require a very time and labor intensive job. 00 so the cost is not a big deal. The guy at the exhaust shop told us not to ever undo from there because they usaully break from all of the heat. The Exhaust Manifold Bolt Repair Bracket will repair the exhaust leak without having to remove. 8 engine will eventually have it: a crack in the exhaust manifold(s). DIY - Snapped exhaust manifold stud removal Here is a little write up on how to remove the ever-so-common broken exhaust manifold stud, but can be used to get out other broken bolts. I have a broken exhaust bolt on my drivers side head. tam85 wrote:what is the first indication of a broken exhaust manifold bolt? any instructions of how will i remove the exhaust bolt and how much does it cost to replace it? I can hear a slight 'putter' from the manifold that is missing a bolt and there is a leak from the tailpipe. I can't say I blame you avoiding it, I've managed to snap 7 exhaust manifold bolts on my engine, all 6 of the passenger side cylinder head. I replaced the bolts on the driver side, except for the back one that is sheared off flush with the cylinder head. Worst case is the exhaust manifold studs break and if you are replacing the manifolds who cares, breaking would be doing you a favor. Labor costs are estimated between $483 and $611 while parts are priced at $1787. This would be a big mstake, because it puts some of the mounting bolts into a bind and that can lead to broken mounting bolts. Trailblazer/Envoy/etc 4. Dealing with challenges associated with removing broken exhaust manifold bolts ProMaxx repair kits are engineered to improve ease and repair times when removing and repairing the exhaust manifolds in Dodge, Ford, GM and Jeep engines. The Studfix clamp is and easy to install clamp that is a great alternative to replacing rusted or broken exhaust studs. 8 liter V6 engine is prone to developing exhaust manifold problems due to cracks, failed gaskets, and loose or broken bolts. This is a discussion on Broken exhaust manifold bolt within the External Engine forums, part of the LSx Technical Help Section category; Damit! ! Every thing was going so well all the bolts were coming out no. 8 engine will eventually have it: a crack in the exhaust manifold(s). It was pricey but didn't need a new manifold (a good machine shop can make it flat again by the way) and I didn't have to deal with the broken stud. If you buy a used engine with high miles that has never been taken apart you might break a head bolt when removing the head. Engine is back in now, but was just wondering if its worth the trouble still to try and drill it out. Replacing the intake manifold is difficult, but can be done with the proper care. During valve overlap, when both the exhaust and intake valves are open at the same time, it is possible for these particles to get sucked back into the cylinder. 6006 6007 6048 (or 6048A, or 6048S) 6088 10009* (Exhaust Manifold) Exhaust Manifold Flange Gaskets. Broken Exhaust Manifold Stud(s) 2004 F250 4x4 XLT Sport Crew Cab. The rest of the bolt and nut are still attached to the other side of the CI flange. Removing The Exhaust. but price a replacement exhaust manifold first. Broken Manifold Bolt repairs are never fun to deal with, but Beydler's Manibolt Driller® is the best possible solution to a worst case nightmare. Anybody have any experience removing the exhaust manifold and how difficult it may be to do? That's about the next option is to replace that piece. Buy Areyourshop Exhaust Manifold Bolt Repair Kit For KAP169 - No Need to Remove Broken Bolts: Studs & Nuts - Amazon. good luck!. It almost sounds like a misfire or detonation if you are close to it. If your exhaust manifold needs replacement, you're in for a hard procedure. Any thread would do as long as you have a new "bit of circular rod with sufficient thread" (technical term) exposed to clear the manifold flange. Once the exhaust has cooled down try wrenching them loose. Removing exhaust bolts is often a lengthy, difficult and frustrating task for auto mechanics. I broke off a stud while removing exhaust and intake manifolds (forgot to heat it). So as most of you probably know, I've posted several times in the past months about my engine ticking and broken manifold bolts. Remove the bolts that hold the manifold to the cylinder head. Great product at a fair price. Time, well the first one took me about 1 hr to get off, because I had to slide the exhaust tube down the Y pipe before the manifold would come off the studs (OMC used studs n nuts instead of bolts, easier and better than bolts, but the ex tube has to be slid down). Most of us with the 3. Exhaust Manifold Leak. 4th Gen Ram Tech - Cost to repair broken manifold bolts - After looking up the cause for why my Hemi is ticking I found that I have at lease two broken manifold bolts. That's the good news. To access the nuts you will have to remove the manifold heat shield first. Exhaust system components are connected using gaskets and/or clamps, which can also fail with similar results. How to remove broken bolts on exhaust manifold - Answered by a verified Ford Mechanic We use cookies to give you the best possible experience on our website. 7 Cummins exhaust manifold-to-head have been prone to failing at the rear of the head/manifold and the rear-most bolts are the most difficult to get to, always seem to break and once broken are very difficult to remove as they keep breaking when trying to get a tool on them for removal out of the head to be. $2000 sounds like a pretty high price to just remove some broken bolts(new manifold $90, Studs & Nuts $20, Gasket $50 & labor?). So iv replaced all the broken exhaust manifold studs on my engine before I put my new short block in. Check the condition of clamps and mounting bolts or nuts, gaskets and exhaust hangers. They are going to replace it with a new Dorman manifold, gasket, and bolts for $410. How to Remove Rusted Bolts. i would love to get $200 for a job that literally takes 10 min. Thats when people go to youtube searching for things like "how to remove a broken bolt" or "exhaust stud removal". Loosen the bolts (use liquid wrench or wd40 for this will be rusty) exhaust pipe from the exhaust manifold (driver side) and. on the subject of bolts what size manifold bolts go in the 94 l99 i have 2 broken drivers rear and am going to attemp this today 94 Caprice 4. 000km on the odo. it takes longer to twist the broken bolt out than the actually welding. NOTE: Remove broken exhaust manifold studs using industry accepted methods for broken fastener.