Exhaust manifold bolts broken

[Rashod]

I have 3 broken exhaust manifold bolts broken on my 04 GMC Yukon. The 2 rear bolts one a driver side and other on passenger side are broken and then another up front. Should I put new manifolds on and go that route or use the manifold clamp kit?

 

[Joseph Garcia]

Welcome to the Forum from NH.

Broken exhaust manifold bolts are a common theme for these trucks. Folks have discussed this topic here in the Forum in various threads, and they will chime in with their suggestions and perspectives for you.

 

[02Lightning]

I had a couple with heads broken off them. I had a shop do it for me, they welded nuts on the broken bolts and backed them out. I had them replace all of them while they were there.

 

[yates ™]

I had a couple with heads broken off them. I had a shop do it for me, they welded nuts on the broken bolts and backed them out. I had them replace all of them while they were there.

x2 on this.

 

[drakon543]

i would also recommend fixing the issue correctly. you could also purchase a set of arp bolts to replace all the manifold bolts. if a shop does it they will most likely use good bolts but will just be the same grade as the ones that were there. ive never used arp but alot of people swear by thier hardware so has to some merit to thier quality.

 

[OR VietVet]

New manifolds if you have the money but you don't need to. New bolts and studs all around. If you reuse the manifolds then have a machine shop surface the gasket surface so is nice and flat.

 

[2006Tahoe2WD]

I found a broken bolt and used the aftermarket bracket method to "fix" it.
Additional reading on the subject indicated the GM replacement bolts are good and should last a long time, pointing to ARP not really necessary. The bolts may be hard to get out but a good mechanic can do it with welding/reverse drilling/etc./etc.

 

[jcb2]

I have 3 broken exhaust manifold bolts broken on my 04 GMC Yukon. The 2 rear bolts one a driver side and other on passenger side are broken and then another up front. Should I put new manifolds on and go that route or use the manifold clamp kit?

I would drill out and retap to install new studs.
Next time, instead of risking a broken stud, do this. Using a small wire brush and pick tool to remove any rust from the nut/bolt joint. Then apply some Aerokroil and let it soak in overnight if possible but at least for a few hours. Then using a wrench or socket alternately try loosening and tightening and you’ll start to get some movement in the treads. Spray more Aerokroil then you should have a good chance of removing the nut or the entire stud.

 

[OR VietVet]

Best penetrant I have ever used is Aerokroil. If you are going to work on vehicles, especially in rust areas, have it and use it.

 

[2006Tahoe2WD]

I like the stud and nut idea. Maybe there is a kit out there somewhere.