I'm getting ready to install my beutifull Hedman coated long tube headers. While looking over the manifolds I noticed one of the bolts was missing/broken off on the drivers side bottom middle of the exhaust manifold. I've heard of a tool called an EZ OUT will this work? how hard is it to do?

 

If enough of it is sticking out after removing the manifold you can grab it with a pair of Vise Grips & thread it out. soak it with CRC 5-56 or WD-40 first to loosen. Otherwise the drill & Easy out method may work. If not the next step is drill & Helicoil. Good luck.

 

I am not sure if you will have enough room to use the ez out. I would just try to grab it if you can. That sucks. If I had those headers just sitting there looking at me all day while I tried to figure that out I would go mad, or even more so.

Brian

 

Be very careful with the EZ out. If you break one of those (which happens often) it is next to impossible to drill it out. Try to avoid using it if you can, even though I doubt you have enough room to use it. This may or not be useful in this situation, I'm not too sure what shape the bolt is in, but if you can, try to jbweld a socket on there. That just might work for you. I've had to do that in the past. Good luck.

 

There are many ways to remove a broken bolt.
First you have to pull the manifold so you can see what you are trying to do.
If there is any of the bolt sticking out of the head, you are in luck, cause that is going to be the least PITA. soak it with penetrating oil (PB Blaster, WD-40 etc) repeatedly for about 15 minutes, give it a couple of good whacks with a hammer to "wake"it up. then put some vise grips on it good and tight and start working it counter clock wise then clock wise. (loosening and tightening it) to get the rust to let loose, when it moves without a huge amount of pressure unscrew it.
If none of the bolt is sticking out of the head, get a 90* die grinder or drill (I don't know what tools you have, you can probably rent a 90* or buy one, they are alot cheaper/easier than pulling the head), center punch the center of the bolt and drill a 1/8" pilot hole ALL THE WAY THROUGH THE BOLT, be carefull cause when the drill goes through the last part of the bolt you may break the bit in the hole if you are pushing too hard. Be sure to use cutting lube.(the can of PB or WD mentioned earlier will work fine).
Then drill the hole out to 3/16".
Squirt the penetrating oil into the hole repeatedly for about 15 minutes.Get a set of QUALITY broken screw extractors, they are about 1 1/4" long (snap-on, Mac, Craftsman, NAPA) and following the instructions provided in the tool set turn out the bolt. Don't get too strong on the tool cause if it breaks, you will start to hate life.
If the tool spins and doesn't grip the bolt, tap it with a hammer or go to the next larger size extractor.
One technique that has worked for me is to insert the screw extractor and give it a little tap with a hammer to get it seated in the screw and then put either an ice cube or cold spray on the extractor for about 10 minutes. this shrinks the screw and makes it come out.
Left handed drill bits are available and some times will grab the bolt and turn it out for you, if you hold your mouth just right and keep your mind clear of impure thoughts.:
Helicoil is the last resort, some folks think that if a bolt is broken, the only thing to do is to "drill it out and helicoil it".
If you spend some time and be patient, broken bolts can usually be extracted and the hole none the worse for wear.
To Helicoil the hole, you still have to center punch the bolt (to keep the hole in the same location) drill a pilot hole (most likely with a 90* drill) and then open up the hole to the helicoil's specified hole size. So you may as well try to do it right to begin with.
Anyway, that's how I would go about it.
Good luck

 

Thanx fior the Tips they are greatly appreciated. As soon as I get that bolt out the headers are going in, and yes ut's driving me crazy looking at those headers sitting in my living room:lala: