Broken exhaust manifold bolts

Well Ive done it now! I got an exhaust put on a few months ago but they didnt want to mess with the manifold collector bolts so they welded the new pipe onto about a foot of old pipe off of the exhaust manifold. This would have been fine, but when they hung it, the hanger kept coming loose. By the time they fixed it right, the exhaust had already moved around enough to create an exhaust leak at the collector.

Fast forward, I soaked the collector bolts for about 3 weeks with PB blaster. Decided today was the day to replace that collector gasket, but both bolts broke off in the manifold

Is there any way to get those broken bolts out without removing the entire exhaust manifold? I am VERY open to suggestions. Thats folks!

 

ive heard heat and candle wax will loosen them up my self i use a left hand drill and easy out

 

I just installed a new exhaust system and had a similar problem. Wound up pulling the manifolds and towing the jeep to a local shop to have the broken bolts removed from the block and the manifolds. The shop used a combination of bolt extractors and an O2 torch to heat and blow out the broken bolts and studs. Not everyone's solution, but all the torch I currently own is MAPP gas. This cut days off my repair time, and I feel better about the whole system with all new bolts, studs and gaskets.

 

If you have a welder, weld a washer (one size smaller) to the broken stud, then a nut to the washer. The heat should help to loosen it also.

 

Sweet, thanks for the responses guys! I just ended up torching them out which worked pretty well. I just need to pick up a 7/16" tap now to clean up the holes and Ill be in business! Talk about being disgruntled for about an hour though...

 

You used an O2 torch?

 

Yes sir, oxy/acetylene with the smallest tip I own. Not the most graceful way to do it but it came out clean.

 

Today, my buddy and I put headers on his '75 dodge and we heated up all the old bolts with the torch and they came free with no issues at all. Did you do that before hand? A little heat does wonders on rusty bolts.

 

Cool! Glad you got it handled.
The wax trick does work but can be time consuming. Used it this week on a yoke that wouldn't come off a pto shaft even with a heavy duty puller. Heat it up, melt the candle wax in there a couple times then let it sit. The wax acts like a lubricant when everything cools and helps break things free. This was after many attempts with penetrating oil, heat, impact with a hammer, etc.
I'm saying all this for future search references.


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Thanks Nick and Gnome, those are great tips that I will be putting to use next time. I gotta be careful with that wax though Nick, the Jeep may think I'm getting fresh with her

As of now, I am back in business with no super annoying exhaust leak!

 

That's great!
The flames from the last trip was from worsening exhaust leak on our last trip. Found cracks in #1 and #3 header tubes today. Gotta pull the header and weld them up.


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the washer and nut trick works too trick being get a good weld to hold em on

 

I've used that successfully too, but only used a nut, no washer.