Need some help. Broke one exhaust bolt on my 78 even with penetrating oil. Too many years of heating up I suppose and it seemed like it was loose when I started. SO :) the problem. What is the easiest way to replace? Pull the manifolds or try to soak the top with penetrating oil and attempt to back out with two nuts?
--Eric

How much, if any, of the broken stud is sticking out? I often heat the exahust manifold with a torch, turn it bright red, the the bolt will come out if you can get a hold of it. If not you will likely need to drill the bolt out, and retap the hole. Then the original size stud can be put back in. If you can't get to the hole straight with the drill, the manifold will have to come off. Sometimes a broken bolt can be removed with an easy out, but rusted exhaust bolts all most never come out that way.
Without a torch if you can get a part of it with vice grips, soaking a few days may make a difference.

I don't know if you have the room for it, but I bought a tool from sears that consists if a disk shaped cage, with another disk with teeth on it. You attach a ratchet and turn it and out comes the bolt. It saved my life when a bolt broke off in the head. It may be much harder to use on a manifold though. I also used penetrating oil and hit the bolt with a hammer a bunch of times. Just an idea.

Thanks for the ideas. There is about 1 1/2 inches sticking out so I can get ahold of it.
I'm going to try soaking a few days and attempt putting 2 or 3 nuts on the stud and attempt to unscrew with a wrench carefully not to further break it off. If the nuts don't work I'll try visegrips but I doubt it will be better than the nuts. I'll let you all know what works.

--Eric

I had that happen to me last spring but it was all six studs. Believe me if you can get a tourch to the manifold and get at it with vice grips you will be real lucky. Unfortunetly mine all broke off with very little sticking out. I took a look at taking off the manifolds but those bolts looked as bad as the studs. It took two days with extended drill bits and a 3/8" ratchet with extension and special socket the hold the tap to fix the problem. Believe me if this ever happens to me again I think I would sell the car. Mine is an 80 and there is so much stuff hanging over and attached to the manifolds, drilling and tapping was the best solition. If you have to drill & tap start with a small bit and step up to the size you need to tap out the hole. Its not fun but it will work. Wish you all the luck.

Thanks Glenn

Thanks for all the support!
The bolts are soaking now. I think I'll try to replace them all. I'll respray in the morning and give a go tomorrow night.
Praying I don't have to drill and tap.

--Eric

The easy way to get frozen studs out of cast iron manifolds is to use a cutting torch. WHAT!?!?,Yes a cutting torch, I've done it many times,the melting point of the bolt is very much lower than the cast iron manifold. Cut the stud flush with the bottom of the manifold, drill a hole through the center of the stud, hold the cutting torch about 1 to 1.5 away from the stud directley over the center of the stud. You'll actulley see the bolt melt away from the threads, chase the treads with a tap. If you think I'am nuts, try it on a broken mnifold

And yes, the manifolds have to be out of the car

Heat the manifold to red hot. It's the only way to go. Those studs will usually come right out. Replace them with the stainless steel stud kit and brass nuts. Be sure to heat the cast iron, not the studs, and be careful beating on it, there is not a lot of material there and you could break off part of the flange.

|UPDATED|4/18/2004 6:41:13 PM (AZT)|/UPDATED|