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broken exhaust mainfold bolts

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Old 09-04-2006, 11:20 PM
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Car: 2000 f-150 truck
Engine: triton
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broken exhaust mainfold bolts

hi, anybody had problems with the back exhaust manifold bolts being broke off, our 88 has the back top and bottom bolts broke off on both sides, any help on getting them out would be helpful thanks
Old 09-04-2006, 11:29 PM
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Car: '82 formula clone, 95 saab 900se
Engine: 350 vortec'd tbi, 2.0L turbo
Transmission: 700r4, 5 spd
Axle/Gears: 10 bolt 2.77 open
drill them and use an ez out bit if you can get it in there, that's all the advice i can give
Old 09-05-2006, 12:04 AM
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Car: 1985 reliant saloon
Engine: 2.2 pile of metal
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Axle/Gears: so tall theres no point
i agree with the easy out, good thing
Old 09-05-2006, 04:12 PM
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A can of PB Blaster and a set of vice-grips...worked for me.
Old 09-05-2006, 04:37 PM
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They are a B---Itch!! The easy out did not work for me, mine were broke off in the head flush.After much experimenting with many kind of drill bits ($$) I finally tried the Dewalt Titanium and it without a doubt worked best.
I bought 3 sizes ( 1/8, 5/16, 3/8 ) and alternated them.Even after days of drilling (I had 4 broken ) I could only get about 1" deep.I then quit and installed Heli-coils. They worked great.
One word of CAUTION...BUY NEW BOLTS, dont try to re-use your old ones.
I made that mistake and when torking down my last bolt...it broke.
so, I cost myself 5 more hours of drilling.
This was a HUGE rookie mistake that will never happen to me again !!
Old 09-05-2006, 06:21 PM
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Car: 2000 f-150 truck
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thanks alot for your info!!!!
Old 07-21-2009, 09:06 PM
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Car: 1991 Chevrolet Camaro RS
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Axle/Gears: 3.23
Re: broken exhaust mainfold bolts

ya i also have two broken bolts flush with the heads. im not sure what too do. no room to drill (it has a carburated 350) and we even welded a washer onto it, and then a bolt and it still wouldnt budge, just kept breaking off. we have a miller high voltage welder by the way. im think about just throwing the headers on and putting some exhaust sealer around the broken bolt area. how would u think this would work guys?
Old 07-23-2009, 05:43 PM
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Car: 89 RS Camaro
Engine: fuel injected 2.8 6 cyl
Transmission: Automatic
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Re: broken exhaust mainfold bolts

hahaha The same thing happened to me..... ahhh it sucks.kinda makes you wanna... beat your grandmother. and even though this wont solve your problem... at least it takes your mind off the fact that its gonna be a pain in the @$$ trying to drill the back bolt out on the manifold. ESPECIALLY if its like mine and is at the bottom in the back idk if i have to pull the motor to get it. i just let it leak. prolly not the best idea... but if you rlly dont like your 2.8 to begin with... it gives a great excuse to get a new motor when the old one craps out. which i believe is right around the corner for mine.
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