Busted Exhaust Manifold bolt!
Thread Starter
Drifting
Joined: Apr 2001
Posts: 1,337
Likes: 52
From: Wentzville, MO.
Busted Exhaust Manifold bolt!
Busted the head of a bolt off while putting on headers, pretty much flush with the head... I wanna throw up... Can anybody advise me on how to get it out? :confused: :sad:
It is the front manifold bolt.. so it will surely leak ...
[Modified by 99SilverC5Coupe, 3:43 PM 2/27/2004]
It is the front manifold bolt.. so it will surely leak ...
[Modified by 99SilverC5Coupe, 3:43 PM 2/27/2004]
Safety Car
Joined: Sep 2003
Posts: 3,558
Likes: 2
From: Cape Coral FL
Re: Busted Exhaust Manifold bolt! (99SilverC5Coupe)
There is a procedure to take out bolts and stripped studs in the service manual. I'm at work and my whole computer system is taken apart at home. I am putting it back together tonight and if you are interested I could send you the proc via email or fax. I can scan it and send you pictures of the pages. Let me know. That really makes me :U
Le Mans Master
Joined: Oct 2002
Posts: 6,855
Likes: 2
From: Grovetown GA
Re: Busted Exhaust Manifold bolt! (ArKay99)
:sad: :sad:
There are kits to remove broken bolts from aluminum - but I would go with the manual procedure. I would sure be :cuss :cuss a lot. Having done this on other cars I know your feeling! :cry It happens when you work on a car!
I hope it comes out clean!
There are kits to remove broken bolts from aluminum - but I would go with the manual procedure. I would sure be :cuss :cuss a lot. Having done this on other cars I know your feeling! :cry It happens when you work on a car!
I hope it comes out clean!
Drifting
Joined: Sep 2002
Posts: 1,614
Likes: 7
From: South Florida
Re: Busted Exhaust Manifold bolt! (99SilverC5Coupe)
I'm doing the headers in a couple of days. Just trying to prevent a problem on mine...Were you torquing them to the factory speck or hand tightening them and got a little overzealous?
Sorry about your bolt. :(
Sorry about your bolt. :(
Pro
Joined: Sep 2003
Posts: 731
Likes: 0
From: Calgary Alberta
Re: Busted Exhaust Manifold bolt! (99SilverC5Coupe)
You can either use an easy-out, or if there is enough stud sticking out you could use mini channel-locks.
Always use a 1/4 inch socket set when installing headers on aluminum heads.
Always use a 1/4 inch socket set when installing headers on aluminum heads.
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Safety Car
Joined: Jan 2001
Posts: 3,879
Likes: 3
From: Hobart, WI
Re: Busted Exhaust Manifold bolt! (99SilverC5Coupe)
Big difference if it is broken off flush.. If not pull the rest of the bolts out and sneak in behind flange with channel locks. Good news is it not stripped.
Instructor
Joined: Jul 2003
Posts: 239
Likes: 1
From: San Jose CA
Re: Busted Exhaust Manifold bolt! (99SilverC5Coupe)
EZ-Out is the ticket. I recommend drilling at least 1/4 in on the first go or you may not get enough grab on the inside of the bolt to back it out, in which case you'll just wear the metal away on the interior of the bolt and have to go bigger on the EZ-Out. You want to avoid going so big on the EZO that you damage the threads in the heads. Better to drill a deeper narrow hole in the broken stud than to go shallow and wide.
Drifting
Joined: Jul 2000
Posts: 1,818
Likes: 3
From: SoCal
Re: Busted Exhaust Manifold bolt! (Rob Razor)
I doubt you'll be able to get a drill in there for an easy out, like others had suggested.
Sooo....
Take a dremmel with a thin cutting disk on it, and cut a groove into the bolt that remains in the head. It will cut a tiny bit of the head too, but it'll be fine right there.
Then, get a stubby screw driver (flat head obviously) and put it in the groove...turn the bolt counter clockwise, and rejoice.
Sooo....
Take a dremmel with a thin cutting disk on it, and cut a groove into the bolt that remains in the head. It will cut a tiny bit of the head too, but it'll be fine right there.
Then, get a stubby screw driver (flat head obviously) and put it in the groove...turn the bolt counter clockwise, and rejoice.
Le Mans Master
Joined: Oct 2002
Posts: 6,855
Likes: 2
From: Grovetown GA
Re: Busted Exhaust Manifold bolt! (Rob Razor)
Crawling around my car it looks like access is not good to get at the bolt. If you do not mind let me/us know the final solution!
Other than this - how did the headers go on?
Looking to do this on my car as soon as I can schedule it in.
:steering:
Other than this - how did the headers go on?
Looking to do this on my car as soon as I can schedule it in.
:steering:
