Hello
I have a exhaust manifold bolt that has snaped off. I heard its a common problem with stock manifold for my engine. My question, although probably easy, is how do you back out the bolt stuck in the engine? I haven't tried doing it yet so i'm hoping to get some help before i start. Any ideas are appreciated ,
Thanks ,
Dave

first how much is sticking out? i mean can you grab ahold with vice grips? if not buy an easy out bolt remover. and always lube up all bolts with penetrating oil prior to removal helps them come out a little easier:D

soak it w/ PB Blaster, drill a hole in it, and back it out with a EZ-out. Just don't break off the ez-out.

You need one of my buddy's handy dandy left handed drill bits!
No lie, he makes them himself on a mill just for removing broken bolts.

He gets a kick out of loaning them to people and not telling them they're left hand twist.:D

If you can't get it out yourself you're gonna have to remove the head, take it into a machine shop and have them remove it which will still be cheaper then another head. Even if you do slightly mess up the threads you can always get a HeliCoil kit and re-thread the hole but I myself would go the machine shop route. Better safe then sorry.

You can actually buy left handed drill bits.
Once you get the stud out, make sure when you reinstall you use an antisieze compound, much easier to remove in the future........:skull:

Thanks for the help,
this seems to be a job that i can do.
Thanks again
-Dave

Well, I just broke a the steering limit bolt off in my D60 last week. Broke off flush with the hub so I took the hub off and drilled it to use an ease out. After 2 days of PB Blaster, Mouse Milk, repeated heating cycles, and fooling with the largest ease-out I could get in there, I got a little to "determined" and broke the ease-out off in the hole. I didn't have a single drill bit (carbide, etc.) capable of even scratching that ease-out. So, I grabbed my new MIG and welded the broken ease-out to the remaining bolt. Figured it should be strong as hell with the ease-out incorporated. Plus, that throws some serious localized heat into the bolt to hopefully break it free. Anyway, I continued to build up a head on the bolt just over 1/4" high. Then I took a pair of vice grips and worked it for about 10 minutes to FINALLY get the damn thing out. If the grips hadn't worked, I was thinking of welding a nut onto the top of the pedestal (now that it was high enough to do it). Anyway, just another thought, just in case the ease-out doesn't cut it...

thanks for the help
-Dave

I use the method that baddog uses (welding a nut to the broken bolt/stud) but i put a washer on the broken bolt piece before the nut so I dont weld the bolt to the head/block/whatever I am working on ..