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Removing a broken exhaust manifold bolt?

Discussion in 'Motors' started by Stonedofmoo, 17 May 2006.

  1. Stonedofmoo

    Soldato

    Joined: 24 Oct 2002

    Posts: 6,245

    Location: Portsmouth

    Any tips on his this can be done. I noticed a bolt was missing on the 9-5 the other day and on closer inspection it's not the bolt is missing, just the head of the bolt :rolleyes:
     
  2. Enfield

    Soldato

    Joined: 8 Nov 2003

    Posts: 7,396

    Location: Hampshire

    Drill it.
     
  3. Foghorn Leghorn

    Wise Guy

    Joined: 5 Jul 2003

    Posts: 2,401

    Location: Cheshire

    Lots of WD40, lock two nuts together on the remaining stud and then undo it with the bottom nut of the two.

    Hope this makes sense :D

    Fog

    i wouldnt drill it unless I absolutely had to, starts to get messy if you run into problems. Depends on how much room you have to play with.
     
  4. Stonedofmoo

    Soldato

    Joined: 24 Oct 2002

    Posts: 6,245

    Location: Portsmouth

    Actually that made no sense to me at all lol

    Explain that again please mate :)

    To elaborate further the sheared nut is recessed in the hole so there is nothing to grasp onto...
     
  5. mr jamez

    Hitman

    Joined: 23 Nov 2003

    Posts: 755

    With the manifold removed is there any stud at all coming out of the head? if so a stud extractor (or the two nuts cheaper method) might do it, after using heat and a decent penetrating oil of course. Trouble is if you take the manifold off, you may end up with even more snapped studs.
     
  6. Simon

    Capodecina

    Joined: 21 Oct 2002

    Posts: 23,391

    Location: Berks / Moscow

    Will taking the manifold off expose more of the bolt?

    These are nightmare bolts to get out as the reason it sheared was probably due to it corroding in. It won't come out without a fight :(
     
  7. Foghorn Leghorn

    Wise Guy

    Joined: 5 Jul 2003

    Posts: 2,401

    Location: Cheshire


    Aaah, that shot my idea down then :o

    It sounded from your post that you had a long bolt sticking out minus the head.

    Like Simon said, I think the best way is to take off the mainfold. But it probaly wont be fun.

    Fog
     
  8. Stonedofmoo

    Soldato

    Joined: 24 Oct 2002

    Posts: 6,245

    Location: Portsmouth

    Righto, a job for a long weekend then by the sounds of things :)
     
  9. Dogbreath

    Capodecina

    Joined: 18 Oct 2002

    Posts: 16,653

    Location: Devon

    If there is any bolt protuding after you remove the manifold welding a nut onto the end nearly always works.
     
  10. Gav

    Wise Guy

    Joined: 21 Oct 2002

    Posts: 1,378

    Location: Republic of Scotland

  11. dalex

    Hitman

    Joined: 14 Jan 2005

    Posts: 809

    Location: gatesheed(gods country)

    is it actually blowing ,if its not just leave it alone as it could turn into a very expensive job
    if you need to do it, spray all nuts and bolts for a couple a days with a good penetrating oil
    remove the manifold and remove stud with stud extractors
    dave
     
    Last edited: 17 May 2006
  12. Cyanide

    Mobster

    Joined: 5 Mar 2006

    Posts: 3,968

    Location: Nottingham

    [​IMG]

    It's the only way to be sure :(


    The best way I know of is to drill and re-tap, assuming you have all the right tools :)
     
  13. Simon

    Capodecina

    Joined: 21 Oct 2002

    Posts: 23,391

    Location: Berks / Moscow

    I agree, if its not blowing leave it
     
  14. Sputnik II

    Mobster

    Joined: 5 Nov 2004

    Posts: 2,547

    Thats what I always do and its never failed yet. Not only does it give you a new hexagonal head to use but the heat produced from welding it breaks any corrosion bond or threadlock adhesives that might have been used on it.

    Those 'easy-out' things are complete rubbish. If the bolts so tight that the head snaps off, they won't ever get it out.
     
  15. Foghorn Leghorn

    Wise Guy

    Joined: 5 Jul 2003

    Posts: 2,401

    Location: Cheshire

    Agreed, stud extractors are utter cr@p for jobs like this (actually, for most jobs :p ), we had a snap on set at work, we got a refund on them in the end they broke that often. Forgot about welding a nut on, sometimes just heating/welding on the end of a stud can be enough to unstick it :D (if you're lucky)

    Fog
     
  16. Stonedofmoo

    Soldato

    Joined: 24 Oct 2002

    Posts: 6,245

    Location: Portsmouth

    I don't know if it's blowing, but I was thinking that it might cause stress on the other bolts being there is a turbo to add onto the weight?
     
  17. Gav

    Wise Guy

    Joined: 21 Oct 2002

    Posts: 1,378

    Location: Republic of Scotland


    You couldnt have been using them right. I have removed hundreds of broken studs/bolts with them and i have never snapped or broken a single one.
     
  18. Foghorn Leghorn

    Wise Guy

    Joined: 5 Jul 2003

    Posts: 2,401

    Location: Cheshire

    Wasn't actually me that kept snapping them, twas my service guys, so possibly. Always found locking two nuts together or welding a nut on worked everytime though Unless its sheered off with no stud protruding, then its out with the drill but thats rare.

    Fog
     
  19. Stonedofmoo

    Soldato

    Joined: 24 Oct 2002

    Posts: 6,245

    Location: Portsmouth

    I think i'll buy a new set of bolts and a gasket sometime and give it a go.