Pennock's Fiero Forum
  Technical Discussion & Questions
  Broken exhaust manifold bolt, removal

Post New Topic  Post A Reply
Email This Page to Someone! | Printable Version


next newest topic | next oldest topic
Broken exhaust manifold bolt, removal by hdryder
Started on: 11-25-2012 05:37 PM
Replies: 22 (2277 views)
Last post by: masospaghetti on 10-15-2013 01:34 PM
hdryder
Member
Posts: 669
From: Virginia Beach, VA, USA
Registered: Apr 2011


Feedback score: N/A
Leave feedback

Rate this member

Report this Post11-25-2012 05:37 PM Click Here to See the Profile for hdryderClick Here to Email hdryderSend a Private Message to hdryderEdit/Delete MessageReply w/QuoteDirect Link to This Post
Has anyone had any success drilling out a broken exhaust manifold bolt in the head, and cleaning threads while the head is on the block?
The 2.8L engine is out of the car in the cradle for a clutch install.

Cylinder #2, top bolt.

Thanks for the help
IP: Logged
PFF
System Bot
Gall757
Member
Posts: 10659
From: Holland, MI
Registered: Jun 2010


Feedback score: N/A
Leave feedback





Total ratings: 88
Rate this member

Report this Post11-25-2012 05:46 PM Click Here to See the Profile for Gall757Send a Private Message to Gall757Edit/Delete MessageReply w/QuoteDirect Link to This Post
IP: Logged
hdryder
Member
Posts: 669
From: Virginia Beach, VA, USA
Registered: Apr 2011


Feedback score: N/A
Leave feedback

Rate this member

Report this Post11-25-2012 07:00 PM Click Here to See the Profile for hdryderClick Here to Email hdryderSend a Private Message to hdryderEdit/Delete MessageReply w/QuoteDirect Link to This Post
Good deal.

Thanks for the help!

[This message has been edited by hdryder (edited 11-25-2012).]

IP: Logged
Spoon
Member
Posts: 3440
From: Sadsburyville, PA. 19369 / USA
Registered: May 2004


Feedback score:    (16)
Leave feedback





Total ratings: 60
Rate this member

Report this Post11-26-2012 10:21 PM Click Here to See the Profile for SpoonSend a Private Message to SpoonEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by hdryder:

Has anyone had any success drilling out a broken exhaust manifold bolt in the head, and cleaning threads while the head is on the block?
The 2.8L engine is out of the car in the cradle for a clutch install.

Cylinder #2, top bolt.



No success here. Nope. None whatsoever. May as well start off with a double shot of "Jack" and a 38 caliber within arms reach. Had to be one of the most miserable jobs I ever encountered in my life.

Spoon

------------------
"Kilgore Trout once wrote a short story which was a dialogue between two pieces of yeast. They were discussing the possible purposes of life as they ate sugar and suffocated in their own excrement. Because of their limited intelligence, they never came close to guessing that they were making champagne." - Kurt Vonnegut

IP: Logged
FieroGT42
Member
Posts: 2992
From: Iowa
Registered: Jan 2005


Feedback score: (4)
Leave feedback





Total ratings: 67
Rate this member

Report this Post11-26-2012 10:41 PM Click Here to See the Profile for FieroGT42Click Here to Email FieroGT42Send a Private Message to FieroGT42Edit/Delete MessageReply w/QuoteDirect Link to This Post
I've done it in and outside the car, and I'd never do it again. I'd sooner drop the cradle, pull the heads and take them to a machine shop.

Good luck and godspeed.
IP: Logged
ltlfrari
Member
Posts: 5310
From: Wake Forest,NC,USA
Registered: Jan 2002


Feedback score: (4)
Leave feedback





Total ratings: 127
Rate this member

Report this Post11-26-2012 11:07 PM Click Here to See the Profile for ltlfrariClick Here to visit ltlfrari's HomePageClick Here to Email ltlfrariSend a Private Message to ltlfrariEdit/Delete MessageReply w/QuoteDirect Link to This Post
No but if you drill them out yourself I suggest a left handed drill. When I had to do one, drilling it was enough to get it loose without having to use an easyout.

------------------
Anything I might say is probably worth what you paid for it, so treat it accordingly!

Dave

www.ltlfrari.com

IP: Logged
hdryder
Member
Posts: 669
From: Virginia Beach, VA, USA
Registered: Apr 2011


Feedback score: N/A
Leave feedback

Rate this member

Report this Post11-27-2012 08:00 AM Click Here to See the Profile for hdryderClick Here to Email hdryderSend a Private Message to hdryderEdit/Delete MessageReply w/QuoteDirect Link to This Post
"left handed drill" ?

Is that a counter-clockwise turning drill bit?
IP: Logged
Dennis LaGrua
Member
Posts: 13645
From: Hillsborough, NJ U.S.A.
Registered: May 2000


Feedback score:    (13)
Leave feedback





Total ratings: 321
Rate this member

Report this Post11-27-2012 08:35 AM Click Here to See the Profile for Dennis LaGruaClick Here to Email Dennis LaGruaSend a Private Message to Dennis LaGruaEdit/Delete MessageReply w/QuoteDirect Link to This Post
Old rusted bolt stubs are difficult to remove. If the bolt stub is sticking out a bit a steel cross member can be welded to it and it turned out with a slotted socket. If the bolt broke off level with the surface of the block, the only easy way to get that bolt stub out is with a special drill jig and stud remover kit that was origiannly used by the dealer ships. They come up on eBay every now and then. You can try center punching the stub and using a reverse drill bit and an easy out but centering the drill can be difficult.

------------------
" THE BLACK PARALYZER" -87GT 3800SC Series III engine, custom ZZP /Frozen Boost Intercooler setup, 3.4" Pulley, Powerlog manifold, Northstar TB, LS1 MAF, 3" Flotech Afterburner Exhaust, Autolite 104's, MSD wires, Custom CAI, 4T65eHD w. custom axles, HP Tuners VCM Suite.
"THE COLUSSUS"
87GT - ALL OUT 3.4L Turbocharged engine, Garrett Hybrid Turbo, MSD ign., modified TH125H
" ON THE LOOSE WITHOUT THE JUICE "

IP: Logged
DimeMachine
Member
Posts: 827
From: Eastern Metro, Minnesota, USA
Registered: Sep 2011


Feedback score: (1)
Leave feedback

Rate this member

Report this Post11-27-2012 09:01 AM Click Here to See the Profile for DimeMachineSend a Private Message to DimeMachineEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by Dennis LaGrua:

Old rusted bolt stubs are difficult to remove. If the bolt stub is sticking out a bit a steel cross member can be welded to it and it turned out with a slotted socket. If the bolt broke off level with the surface of the block, the only easy way to get that bolt stub out is with a special drill jig and stud remover kit that was origiannly used by the dealer ships. They come up on eBay every now and then. You can try center punching the stub and using a reverse drill bit and an easy out but centering the drill can be difficult.



I second this method. I have used it quite a few times. If you can weld a nub with a wire feed onto the end of the broken stud - the heat on the stud expands rapidly and many times will break itself free. I apply a lot of heat by making the nub large enough to grab with a vise grips. let it cool for a minute or two from when the nub is cherry red. Sometimes you will break the nub off - but repeat the process. I used to have a drawer in my toolbox where I kept my prize nubs. When you get that broken stud out it kinda feels like you won something..

------------------
84 Formula Clone, 3800SC, VS Cam, 3.2 Pulley, 4T65E-HD, HP Tuners, AEM Wideband, , Regal GS Gauges, S-10 Brake Booster. 12.53 at 106.5 1/4 mile

IP: Logged
Grantman
Member
Posts: 1410
From: Glencoe, Minnesota, USA
Registered: Dec 2011


Feedback score:    (22)
Leave feedback

Rate this member

Report this Post11-27-2012 11:45 AM Click Here to See the Profile for GrantmanClick Here to Email GrantmanSend a Private Message to GrantmanEdit/Delete MessageReply w/QuoteDirect Link to This Post
IP: Logged
Joseph Upson
Member
Posts: 4929
From:
Registered: Jan 2002


Feedback score: (2)
Leave feedback





Total ratings: 88
Rate this member

Report this Post11-27-2012 12:36 PM Click Here to See the Profile for Joseph UpsonClick Here to Email Joseph UpsonSend a Private Message to Joseph UpsonEdit/Delete MessageReply w/QuoteDirect Link to This Post
I've succeeded at this everytime I've tried it using a dremel tool and a tile grinding bit from Home Depot that has a cutting surface at the tip of the bit. Grind a depression as close to the center of the remaining bolt as you can, then start with the same size or smaller drill bit and drill all the way through it, stepping up the bit size until you've nearly reached the bore of the threads inside the hole. You can use a small punch or screw driver after that to try and collapse the outer hull of the bolt to help remove it afterwards. Did this on my brothers Buick Nailhead about two months ago to remove a broken water pump bolt.

Welding on an attachment is a good method also but it depends on how bad the bolt is seized in place as to whether it will work.
IP: Logged
PFF
System Bot
ltlfrari
Member
Posts: 5310
From: Wake Forest,NC,USA
Registered: Jan 2002


Feedback score: (4)
Leave feedback





Total ratings: 127
Rate this member

Report this Post11-27-2012 12:45 PM Click Here to See the Profile for ltlfrariClick Here to visit ltlfrari's HomePageClick Here to Email ltlfrariSend a Private Message to ltlfrariEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by hdryder:

"left handed drill" ?

Is that a counter-clockwise turning drill bit?


Yes.

------------------
Anything I might say is probably worth what you paid for it, so treat it accordingly!

Dave

www.ltlfrari.com

IP: Logged
Quad Raider
Member
Posts: 865
From: Oologah, Oklahoma
Registered: Dec 2010


Feedback score: (3)
Leave feedback

Rate this member

Report this Post11-27-2012 01:01 PM Click Here to See the Profile for Quad RaiderClick Here to Email Quad RaiderSend a Private Message to Quad RaiderEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by DimeMachine:

When you get that broken stud out it kinda feels like you won something..



Ain't that the truth! I found several broken studs when replacing the head gaskets on my daughter's Lumina over the summer. I used the weld-on-an-old-bolt method because luckily all of the broken studs were sticking out at least 1/8". I was careful to put the vise grips right on the weld, not further up on the bolt, and every stud came right out.

IP: Logged
Francis T
Member
Posts: 6620
From: spotsylvania va. usa
Registered: Oct 2003


Feedback score: (1)
Leave feedback





Total ratings: 119
Rate this member

Report this Post11-27-2012 06:17 PM Click Here to See the Profile for Francis TClick Here to visit Francis T's HomePageClick Here to Email Francis TSend a Private Message to Francis TEdit/Delete MessageReply w/QuoteDirect Link to This Post

1st - Have a machine shop drill it out. Don't mess around with easy-outs etc. If you break one of those it will make it 10x harder to fix as they're high carbon steel
2nd - With the bolt out, there's a lot of meat left that can be drilled into and tapped so you can then use a longer 8mm pitch bolt.

------------------

trueleo.com
RSpiderII@aol.com

IP: Logged
sc2m6
Member
Posts: 103
From: hillsborough nc usa
Registered: Oct 2007


Feedback score: N/A
Leave feedback

Rate this member

Report this Post11-27-2012 06:27 PM Click Here to See the Profile for sc2m6Click Here to Email sc2m6Send a Private Message to sc2m6Edit/Delete MessageReply w/QuoteDirect Link to This Post
hey man ive done exhaust stud extraction for years at uhaul when i worked in the shop. i did them on 6.8L v10s 460ci big block fords power strokes and my own 2.8 in my fiero. the best way that i have come up with (since the 6.8 v10s are shoe horned in the engine compartment not to mention that they have alum. heads) is if theres any stud sticking out at all like they already mentioned welding a steel bolt to it works but while doing that the head MUST be heated up really good. the head will expand and it will be the the easy way. and i have drilled them when there broken off inside and heated the block up really really good and drilled all the way through with a tiny bit (to get pb blaster in the back of the threads) then use a reverse drill bit and 95% of the time it will back out hope this helps some
IP: Logged
Justinbart
Member
Posts: 3259
From: Flint, MI
Registered: Sep 2009


Feedback score: N/A
Leave feedback





Total ratings: 119
Rate this member

Report this Post11-27-2012 06:37 PM Click Here to See the Profile for JustinbartSend a Private Message to JustinbartEdit/Delete MessageReply w/QuoteDirect Link to This Post
Left handed drill bits are awesome. Who ever made easy-outs need to be shot.

------------------
Turbo 3800 E85 F23 5spd spec5
11.17@132.6

IP: Logged
sc2m6
Member
Posts: 103
From: hillsborough nc usa
Registered: Oct 2007


Feedback score: N/A
Leave feedback

Rate this member

Report this Post11-27-2012 07:20 PM Click Here to See the Profile for sc2m6Click Here to Email sc2m6Send a Private Message to sc2m6Edit/Delete MessageReply w/QuoteDirect Link to This Post
I agree about the easy outs.... once you break on off in there the whole meaning of easy out its... well not easy you CANNOT drill one out but left handed bits and a torch will make things a breeze
IP: Logged
fierogt28
Member
Posts: 2778
From: New-Brunswick, Canada.
Registered: Feb 2005


Feedback score:    (14)
Leave feedback

Rate this member

Report this Post11-27-2012 07:32 PM Click Here to See the Profile for fierogt28Click Here to Email fierogt28Send a Private Message to fierogt28Edit/Delete MessageReply w/QuoteDirect Link to This Post
Isn't the 2.8l HO heads still available new??

GM Part # 10054884

I guess the best route to go is using studs and fastening the manifolds with nuts.

Really, its a pain getting out broken bolts outta those heads.
IP: Logged
Purple86GT
Member
Posts: 1592
From: Ontario, Canada
Registered: Mar 2012


Feedback score: (1)
Leave feedback





Total ratings: 62
Rate this member

Report this Post11-27-2012 07:33 PM Click Here to See the Profile for Purple86GTClick Here to Email Purple86GTSend a Private Message to Purple86GTEdit/Delete MessageReply w/QuoteDirect Link to This Post
IP: Logged
fierogt28
Member
Posts: 2778
From: New-Brunswick, Canada.
Registered: Feb 2005


Feedback score:    (14)
Leave feedback

Rate this member

Report this Post11-27-2012 08:28 PM Click Here to See the Profile for fierogt28Click Here to Email fierogt28Send a Private Message to fierogt28Edit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by Purple86GT:

http://www.youtube.com/watch?v=4BFUfGKU_ts


Good link...
IP: Logged
RWDPLZ
Member
Posts: 14400
From: Michigan
Registered: May 2002


Feedback score:    (11)
Leave feedback





Total ratings: 295
Rate this member

Report this Post11-27-2012 10:08 PM Click Here to See the Profile for RWDPLZClick Here to visit RWDPLZ's HomePageSend a Private Message to RWDPLZEdit/Delete MessageReply w/QuoteDirect Link to This Post
Slightly related, changing the power steering belt on my little brother's Honda Civic tonight, and just as I'm bolting it all back together, the tension bolt breaks off in the pump body casting. Drilled and drilled and drilled, sharpened the drill bit, and the little bastard isn't going anywhere. All the while the stupid thing keeps bleeding fluid all over me. A new pump is $250, taking it to a machine shop would be $50+, or one of the local junkyards has 4 of them for $35 each. Guess which one I'm doing. Freaking HATE broken bolts.
IP: Logged
PFF
System Bot
BAD88GT
Member
Posts: 176
From: Idaho Falls, ID
Registered: Mar 2012


Feedback score: N/A
Leave feedback

Rate this member

Report this Post10-13-2013 03:16 AM Click Here to See the Profile for BAD88GTSend a Private Message to BAD88GTEdit/Delete MessageReply w/QuoteDirect Link to This Post
I just found the exhaust leak on the '86 I just purchased... Cyl no. 5- both bolts already broken by PO. The other 4 came out quite easily. Really don't want to pull the head for 2 bolts. I have an angle drill I can fit up in there but it still won't be fun. I figured it is work a try with a left fluted drill bit. Will I be wasting my time?
IP: Logged
masospaghetti
Member
Posts: 2477
From: Charlotte, NC USA
Registered: Dec 2009


Feedback score:    (10)
Leave feedback

Rate this member

Report this Post10-15-2013 01:34 PM Click Here to See the Profile for masospaghettiClick Here to Email masospaghettiSend a Private Message to masospaghettiEdit/Delete MessageReply w/QuoteDirect Link to This Post
I haven't tried it but you can try welding a nut onto a broken stud, even if its flush with the head. Hold the nut up onto the stud and fill it with weld. I can imagine it would be hard to start it but would probably be easier than drilling if you had access to a welder.

If the stud is sticking out enough you can try a stud extractor tool like this one, I only used it once but it worked great:

Titan stud puller

Mayhew stud puller



The bottom one is US-made, the Titan one is from Taiwan.

[This message has been edited by masospaghetti (edited 10-15-2013).]

IP: Logged

next newest topic | next oldest topic

All times are ET (US)

Post New Topic  Post A Reply
Hop to:

Contact Us | Back To Main Page

Advertizing on PFF | Fiero Parts Vendors
PFF Merchandise | Fiero Gallery | Ogre's Cave
Real-Time Chat | Fiero Related Auctions on eBay



Copyright (c) 1999, C. Pennock