Ok, I'm back with the same issue I dealt with years ago on the passenger side when I first bought this coach. That was quite a saga...Now I have 2 broken bolts on the driver's side exhaust manifold - fortunately it's the 2 most rear bolts and I have pretty good access with my right angle air drill. I have removed the manifold and managed to get all of the other bolts without without problems. I am attaching a picture and you can see that the bolts are both broken off about 1-2 mm below the surface of the cylinder head.Any thoughts?Thanks, ryan

Guess I don't know how to post a pic...

Hey Ryan!Where is your Picture "hosted?" There's a new photo posting app in the Forum Tech Support section that should let you do it. If it's already on the WEB somewhere like PhotoBucket, flickR, etc. then that Advanced Post Form icon that looks like a postcard should get you through it.Usually, only the first couple threads are "stuck." So, do you think you can get a good enough shot at the broken bolt to get at least a 3/16" hole through it? By that I mean all the way through. Then spray penetrant so it soaks both ways and gently try an Extractor. I like the straight-fluted ones better than the spirals. A 1/4" hole and a bigger Extractor would be better... There are also Left-Handed Drill Bits. The idea is that they're working to back the broken fastener out, while you drill in reverse, the bit is creating its hole. As the torque and heat of drilling go after it, just might spin out. You'd need GOOD "extractor bits" not the Harbor Fright kind...OH! Another idea. Take a flat-nosed punch, at least 1/4" diameter, and hammer it moderately hard, against the end of that broken piece. I struggled and struggled with the driver side on our old 1983 460. Sprayed it, waited, sprayed, waited, for a week. Finally went after it with a socket wrench and fortunately all eight came out. When I got to the passenger side, the fastener heads were so worn I couldn't use the 9/16" socket. I had to pound a 13MM onto them. Blessing in disguise. I tried a wrench before the spraying/waiting routine, and the first one felt almost loose. Then the next, the next... Got all eight out without spraying, waiting, or breakage. BEAT IT! Before any attempt!Get back with us with a progress report. I'd like to hear how you plan to install the manifold again.Blessings, Brother!

Broken manifold bolts are a longstanding problem with those older Ford 460 engines. I would think by now, there would be a permanent fix for that problem. Have you checked out any of the Ford related forums for a fix? I love the power of that engine, but the manifold bolt problems have driven me crazy in the past.

Hey John,Good to hear from you - hope you're well. I plan to bang on the broken bolts like you described, and have already started spraying them with Kroil...can't get to the drilling until Monday anyway.I also bought some left-hand drill bits - thought I might try that. What about using heat? I have some MAPP gas that I could use - I'm pretty sure this is a cast iron head - would I heat the bolt directly? Any thoughts?I don't think Ford has ever come up with a permanent fix - folks will frequently tell you to get headers, but I have no intention on spending that kind of money on a 24 y/o motorhome...John, I will install the exhaust manifold w/o a gasket - just like this one came off and just like I did the passenger side. I was planning on buying a new manifold, but this one looks pretty good. Might take it somewhere and have it checked and planed...just don't know where to take it.ryan

http://maniboltdriller.com/products/Tool to drill straight and aligned.

'93 Ford 460 - 2 broken exhaust bolts (pic attached)

j-d
Explorer II
Jul 07, 2017
Hey Ryan!

Where is your Picture "hosted?" There's a new photo posting app in the Forum Tech Support section that should let you do it.

If it's already on the WEB somewhere like PhotoBucket, flickR, etc. then that Advanced Post Form icon that looks like a postcard should get you through it.

Usually, only the first couple threads are "stuck." So, do you think you can get a good enough shot at the broken bolt to get at least a 3/16" hole through it? By that I mean all the way through. Then spray penetrant so it soaks both ways and gently try an Extractor. I like the straight-fluted ones better than the spirals. A 1/4" hole and a bigger Extractor would be better...

There are also Left-Handed Drill Bits. The idea is that they're working to back the broken fastener out, while you drill in reverse, the bit is creating its hole. As the torque and heat of drilling go after it, just might spin out. You'd need GOOD "extractor bits" not the Harbor Fright kind...

OH! Another idea. Take a flat-nosed punch, at least 1/4" diameter, and hammer it moderately hard, against the end of that broken piece. I struggled and struggled with the driver side on our old 1983 460. Sprayed it, waited, sprayed, waited, for a week. Finally went after it with a socket wrench and fortunately all eight came out. When I got to the passenger side, the fastener heads were so worn I couldn't use the 9/16" socket. I had to pound a 13MM onto them. Blessing in disguise. I tried a wrench before the spraying/waiting routine, and the first one felt almost loose. Then the next, the next... Got all eight out without spraying, waiting, or breakage. BEAT IT! Before any attempt!

Get back with us with a progress report. I'd like to hear how you plan to install the manifold again.

Blessings, Brother!
rgnprof
Explorer
Jul 07, 2017
Guess I don't know how to post a pic...

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'93 Ford 460 - 2 broken exhaust bolts (pic attached)

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