Getting out broken exhaust bolt?
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Getting out broken exhaust bolt?
Ok, well I've had this problem for over a week now, I broke one of the bolts on the Y-pipe to the passenger side exhaust manifold. I got all the other bolts out fine, but how do I get that one broken bolt out and get a new one it? Is it possible to screw that one out and a new one in? I have some ideas, I guess that couldn't hurt, but does anyone have any suggestions? I'd like to keep the exhaust manifold in the car if possible. Thanks.
Team Owner
Joined: Dec 2000
Posts: 90,675
Likes: 304
From: SE NY
Cruise-In II Veteran
Re: Getting out broken exhaust bolt? (Red91Vette)
To do it on the car you could heat the flange while turning the part extending above; if enough room, you could drill it out.
If you pull the manifold, remove the plastic access panel on the right wheel well to get at the hose clamp that holds the air tube to the flange tang. Oh, and be careful if you bend the oil dip stick tube (it beaks rather easily).
If you pull the manifold, remove the plastic access panel on the right wheel well to get at the hose clamp that holds the air tube to the flange tang. Oh, and be careful if you bend the oil dip stick tube (it beaks rather easily).
Racer
Joined: Apr 2002
Posts: 415
Likes: 0
From: loughborough Leics ENGLAND
Re: Getting out broken exhaust bolt? (Red91Vette)
If you have access to a mig welder
( or someone who can bring one to you )
Just weld a washer to the broken stud
( even if it has broken off flush it will still work )
Then weld a nut to the washer by filling the threaded hole in the nut.
This really does work every time and is so dam easy if you have a welder
Then just wait until it has stopped glowing red and remove by using a socket in the normal way.
:cheers:
( or someone who can bring one to you )
Just weld a washer to the broken stud
( even if it has broken off flush it will still work )
Then weld a nut to the washer by filling the threaded hole in the nut.
This really does work every time and is so dam easy if you have a welder
Then just wait until it has stopped glowing red and remove by using a socket in the normal way.
:cheers:
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Re: Getting out broken exhaust bolt? (BLUE ONE)
So I assume it screws into the header? Not pressed? I think I might be able to get the bolt out, maybe, I am about to go work on it now. Then I will have to get a new stud and put a lock nut on it and thread it back in the exhaust manifold, think that will work? I don't want to take the manifold off, I don't have a welder either, hopefuly I can get it out and get a new stud tomorrow at work and have this car running tommorrow night. Thanks guys.
Racer
Joined: Apr 2002
Posts: 415
Likes: 0
From: loughborough Leics ENGLAND
Re: Getting out broken exhaust bolt? (Red91Vette)
The ones on my 90 manifolds screw in so a guess yours do too.
If there is enough thread to get a a couple of thin nuts on that would be worth a go but it depends why the stud broke in the first place.
Heat is what you need if its stuck.
I have never had much look with the easyout extractors but hey it could just be me.
Hope it goes your way
:cheers:
If there is enough thread to get a a couple of thin nuts on that would be worth a go but it depends why the stud broke in the first place.
Heat is what you need if its stuck.
I have never had much look with the easyout extractors but hey it could just be me.
Hope it goes your way
:cheers:
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Re: Getting out broken exhaust bolt? (BLUE ONE)
Well atleast that gives me some hope, since they screw in, then there is a better chance I have to get them out. I have a torch, but its raining non stop where I live, and I can't use the torch in the garage! Well Ijust picked up some bolts and nuts etc. and im gonna see what I can do, thanks. I remember you asked about the TPIS cold air induction too, my brother Tpivette89 was going to do the test? Well it still hasn't come yet, hopefully it does so this friday so he can test it out and mabye I'll have my Y-pipe in.
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Re: Getting out broken exhaust bolt? (Red91Vette)
D@MN IT!!!!!!! IM SOO PISSED!!!!! I can't get the broken stud out! I can't get the exhaust manifold off either! There is too much stuff in the way and im afraid I'll break those bolts in the head. The stud isn't going anywhere, neither is my exhaust manifold, so I guess the car isn't going anywhere too. D@MN IT I hate this! I wonder if I can sell the vette and have enough money to buy a honduh?
:mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad
:mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad :mad
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
Top 10 Most Expensive Corvettes Ever Sold on Bring A Trailer
Brett Foote
10 Things Every Corvette Owner Needs (2026 Edition)
Michael S. Palmer
8 Most "Only Corvette Owners Understand" Quirks and Problems
Pouria Savadkouei
10 Reasons the C6 Z06 is Still A Performance Benchmark After 20 Years
Joe Kucinski
How Much Horsepower Every Corvette Engine "LOST" in 1972
Joe Kucinski
Top 10 DOs and DON'Ts for Protecting Your Convertible Top!
Michael S. Palmer
Top 10 Most Explosive Corvettes Ever Made: Power-to-Weight Ratio Ranked!
Joe Kucinski
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Re: (scorp508)
The AC compresser is in the way(I think that is what it is, im not too sure) Im afraid of snapping one of the bolts, then I'll have to pull the heads! Did you move anything to get all 6 exhaust manifold bolts out? I wonder if there is any difference between our engines, that would makeit harder on mine then yours? I don't know, this really sucks, I wish I could take it somewhere, but no one would do it!
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Re: (scorp508)
CF IM isn't working for me for some reason? Do you mean thats how to take the exhaust manifold off the car when the bolts are out? Im sure I could get that out, but I haven't even gotten a bolt out yet. The AC compresser or whatever it is, is blocking the first two bolts all the way to the right. The middle two ones seem easy, the two to the left seem a bit hard. Did you move anything to get to the bolts? These bolts seem near impossible to reach!
Racer
Joined: Apr 2002
Posts: 415
Likes: 0
From: loughborough Leics ENGLAND
Re: (Red91Vette)
On my 90 the two center ones are easy, the two towards the rear are a pain but doable.
The two at the front ( under the a/c unit ) can be got at with a long extension from the wheel housing area with a bit of wriggling and a uj if you need one. I that does not work then remove the four 10mm bolts holding the a/c unit onto the bracket and move it out of the way
( i did not have to do this on my car )
To get the manifold out you will have to lower one end and raise the other ( be careful not to earth out on the starter, ie disconnect battery to be safe )
:smash: Be paitent its a bummer, i know but you would not be happy with a hunda would you :eek:
:cheers:
The two at the front ( under the a/c unit ) can be got at with a long extension from the wheel housing area with a bit of wriggling and a uj if you need one. I that does not work then remove the four 10mm bolts holding the a/c unit onto the bracket and move it out of the way
( i did not have to do this on my car )
To get the manifold out you will have to lower one end and raise the other ( be careful not to earth out on the starter, ie disconnect battery to be safe )
:smash: Be paitent its a bummer, i know but you would not be happy with a hunda would you :eek:
:cheers:
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Re: (BLUE ONE)
Ok, well Im am slowly starting to get this exhaust manifold off, wow, I didn't know I'd have to take off the wheel well to get those two bolts. The two farthest to the left, I couldnt reach with a rachet, but I can with a breaker bar. Hopefully this all works out, then I still have to get that old stud out and a new one in :crazy: When will it all stop! Atleast a honduh will run! But I think I'd walk faster. I gotta go to work now, soon as I get home that manifold is coming off! Hopefully! Thanks.
Racer
Joined: Apr 2002
Posts: 415
Likes: 0
From: loughborough Leics ENGLAND
Re: (Red91Vette)
You should be able to get the bolts by going through the hole were the top suspension arm goes through the wheel well, you do not have to remove the wheel well.
It will all be over soon :flag
:cheers:
It will all be over soon :flag
:cheers:
Race Director
Joined: Jul 2001
Posts: 14,604
Likes: 3
From: Glendale, AZ
Re: Getting out broken exhaust bolt? (Red91Vette)
i had to drill mine out from underneath! burnt out a drill in the process! however i kept my drill bits small and i didn't have to re tap the hole, as when i was drilling and moving on to slightly larger bits, it worked its way out of the flange to the top as if i were tightening it all the way through!
Team Owner
Joined: Dec 2000
Posts: 90,675
Likes: 304
From: SE NY
Cruise-In II Veteran
Re: (Red91Vette)
To get the right side exhaust manifold off remove the A/C compressor bolts and support and move it forward.
Remove the EGR tube. Use lots of Liquid Wrench on the two outer bolts and rap the Torx bit extension a copla times to loosen them. Then apply plenty of down pressure so as to not strip the bolt heads.
The two AIR tubes should come out too; can't recall if the AIR diverter has to move or not.
Remove the dip stick clamp from the header bolt and the AIR tube clamp (through the wheel well opening). Here be very careful to not bend the dip stick tube very much as it car break easily.
Do NOT remove the heat shields from the header, remove them as a unit.
The header bolts should come right out as they are into Al heads.
It realy isn't that bad, just a lot of preliminary work.
Pick up a set of OEM exhaust manifold gaskets at the Chevy dealer.
I can't remember if I used LockTite or AntiSieze on the exhaust manifold bolts?? Maybe someone here will come to the rescue on this one.
If you can't get the broken bolt out on the bench, just take the header to a good shop to avoid the frustration (better than getting the Honda).
[Modified by 65Z01, 12:40 PM 11/18/2002]
Remove the EGR tube. Use lots of Liquid Wrench on the two outer bolts and rap the Torx bit extension a copla times to loosen them. Then apply plenty of down pressure so as to not strip the bolt heads.
The two AIR tubes should come out too; can't recall if the AIR diverter has to move or not.
Remove the dip stick clamp from the header bolt and the AIR tube clamp (through the wheel well opening). Here be very careful to not bend the dip stick tube very much as it car break easily.
Do NOT remove the heat shields from the header, remove them as a unit.
The header bolts should come right out as they are into Al heads.
It realy isn't that bad, just a lot of preliminary work.
Pick up a set of OEM exhaust manifold gaskets at the Chevy dealer.
I can't remember if I used LockTite or AntiSieze on the exhaust manifold bolts?? Maybe someone here will come to the rescue on this one.
If you can't get the broken bolt out on the bench, just take the header to a good shop to avoid the frustration (better than getting the Honda).
[Modified by 65Z01, 12:40 PM 11/18/2002]
Thread Starter
Pro
Joined: May 2002
Posts: 510
Likes: 0
From: Hockessin DE
Re: (BLUE ONE)
I hope mine haven't siezed up yet! Well today when I get home from work I am going to see if I can get another bolt out. Do I have to take the wheel off? I am a little worried about moving the AC because when I go to put it back together, something might not go back right or it will be off a little and throw the belt? We will have to see tonight. I keep details posted, thanks everyone.
Le Mans Master
Joined: Mar 2001
Posts: 7,999
Likes: 14
From: Life is just one big track event. Everything before and after is prep and warm-up and cool-down laps
Cruise-In III Veteran
Cruise-In IV Veteran
St. Jude Donor '12
Re: (Red91Vette)
II am a little worried about moving the AC because when I go to put it back together, something might not go back right or it will be off a little and throw the belt? We will have to see tonight. I keep details posted, thanks everyone.
If you have to remove the mounting bracket scribe a couple of alignment marks before you losen it so you put it back where it was.
Good Luck, take your time. I'm pulling my exhaust in a couple of months.
Racer
Joined: Apr 2002
Posts: 415
Likes: 0
From: loughborough Leics ENGLAND
Re: (Red91Vette)
You do not have to remove the wheel.
If you want to remove the a/c don't worry because you will take the pump of the bracket and it can only go back the way it comes off.
I don't think you need to take it off to get that bolt so stick at it.
:D :cheers: :D
If you want to remove the a/c don't worry because you will take the pump of the bracket and it can only go back the way it comes off.
I don't think you need to take it off to get that bolt so stick at it.
:D :cheers: :D