Easiest way to remove a broken bolt from the exhaust manifold?

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Lesley

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Bolt busted on my exhaust manifold, it's stuck tight, tried grabbing it with pliers and hand working it out, not enough room to break it loose, don't wanna drill it out and have to rethread. Any suggestions?
 

1BADI5

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Grab a shoulder nut and weld it to the remains of the bolt.

Now you'll have something to back out and with added heat it should back right out
 

sumo

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Without Messing with the broken stud, there is a manifold clamp made by KAP Kral. There are threaded holes in your block above the manifold. They use those holes and the clamp part goes over the manifold. They make clamps that fit for what ever stud is broken. Depending on what stud is broken, I have one that I didn’t need and it’s for the passenger side rear or maybe it’s the front stud. I’d have to look at it.

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mals

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I had four broken exhaust manifold bolts, front and rear bolt on each side, on my Yukon when I purchased it. I looked into the clamps, but for the cost of getting all four corners, I decided it was worth the effort to get them out. I soaked them daily for a week with penetrating oil, and then dropped it off at a trusted mechanic. Three of the bolts had just sheared off at the head and there was enough of the bolt proud of the head that they could weld on a nut as a replacement head and back them out. The forth one was flush with the head, and the drilled out the center of the bolt and backed it out with an EZ-Out extractor. They charged me 4 hours of shop time for the entire project including putting it back together with new gaskets and ARP header bolts that I supplied.
 
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1BADI5

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I'm just a firm believer in doing it right the first time. I leave short cuts for field expedient uses only.
 

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