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I was going to replace the starter in my 99 Vette today and had a rough start. In order to get to it, I had to remove the intermediate exhaust piping which is bolted on to the exhaust manifold. When undoing the first bolt, it actually broke off! The nut itself never really moved, the bolt just twisted and broke. I was afraid to remove any of the others in case they did the same thing. Obviously, the started never got changed out. From what I can tell, that bolt is actually part of the exhaust manifold, and I am afraid I will have to replace the entire manifold. Any words of wisdom on this area? I am pretty pissed about this. Thanks.
1. Use plenty of WD-40 or similar stuff. Letting the exhaustnuts soak overnight is a good idea. Use a rag to retain the lubricant aroud the nut.
2. Try to loosen all the nuts. Do not apply too much brute force. Do not use a huge breaker bar. Knowing exactly how much force to apply generally comes with experience and depends on the thickness and thread of the stud.
3. If tou are unsuccessfull with loosening the nuts, it's time to get one of them miniature torches to work. Be extremely careful, it's very easy to set the car on fire, much easier that most people think. WD-40 and the likes are flammable. Keep a fire extinguisher handy.