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help removing broken exhaust manifold bolts

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Old Jun 4, 2026 | 09:43 PM
  #1  
rustyjones85's Avatar
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help removing broken exhaust manifold bolts

i desperately need to be pointed in the right direction.
my passengers side exhaust manifold finally came out, but i have broken bolts. they snapped off when threading out, and are stuck pretty deep in the thread.
unfortunately due to the location of the car and lack of tools, lifting the motor is not an option for me.
a/c box is already removed, i will attach a photo of my work space.
shhh i know it looks awful
shhh i know it looks awful
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Old Jun 5, 2026 | 08:53 AM
  #2  
72buickgs's Avatar
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Joined: Oct 2021
Posts: 745
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From: Windsor, On
Car: 1984 Trans AM
Engine: 305
Transmission: 700-4r
Axle/Gears: 3.23
Re: help removing broken exhaust manifold bolts

With the remains of the bolt tops too far into the head to weld a bolt onto them, then olny solution that I know is to drill them & try an easyout to attempt to remove the broken bolts.
In the future, oldtimers would use a big ballpean hammer to beat on the bolt head to attempt to loosen the bolts. Did that on the exhaust manifold bolts many years ago & no broken bolts.
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Old Jun 5, 2026 | 07:30 PM
  #3  
tbroadfoot125's Avatar
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Joined: Jun 2012
Posts: 88
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From: Andover, Ohio
Engine: 87 5.0L TPI
Transmission: 700R4
Re: help removing broken exhaust manifold bolts

Soak them down with some Kroil penetrate for a while, drill and easy out them is about your only choice I know of. The Kroil oil is somewhat expensive but it really works! Deep creep works really well also but not as good as the other stuff. If there is anyway to thread another bolt in, drill through a spare bolt and use it as a drill guide so you will hit near center of the broken bolt with your drill bit.
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