Okay, I'm trying to remove the exhaust manifold from my wife's 96 Pontiac Sunfire 2.4l so I can replace the water pump. The bolt that holds the manifold to a support brace near the bottom of the manifold is froze tight and the head is beginning to strip, allowing sockets and wrenches to just slip off of it. There is not enough room to get a pair of vise-grips on it and the brace itself cannot just be easily unbolted from the engine and come out with the manifold, so the easiest two options have already been explored. I also sprayed some WD-40 on it and allowed it sit for awhile, also to no avail. My next thought is to J-B Weld an old socket to the bolt head, allowing it to cure overnight, and then giving it another try. Any thoughts on this or any other suggestions or tips on how to get this bolt out? I haven't tried the heat gun yet. Would that help any? I could really use some help on this one, guys!

Given that you are probably replacing the water pump for overheating problems you might want to be careful, but you might want to run the engine for a bit to warm things up a little bit then try. Metal expands when warm and it has gotten me out of some binds in the past. Good luck to you!

If you have access to a welder you can try welding another nut or bar to the head of the bolt and use that piece to loosen the stuck bolt. I have tried this and it works well if you have enough room and do not break off the bolt.

It's unlikely that the JB Weld will work. If all else fails and you really can't get at it with vice-grips (my favorite tool), maybe you can grind the head off with a dremel tool and then after the water pump is off, clamp onto it with vice-grips and unscrew the remains of the bolt (see, I'll get you to use those vice-grips yet).

[This message has been edited by batboy (edited 04-26-2000).]

If you have access to a torch, heat works wonders on rusty bolts. I bought a little propane/oxygen one for $30 or $40. It has helped me easily loosen several bolts/nuts that I have no idea what I would have done with otherwise. Get it as hot as practical. Many times it will then come out with minimal effort.