I have recently been experiencing exhaust leaks from my exhaust manifold, and it looks like I have a couple broken bolts on the manifold itself, which is where I think the leak is coming from. I have an 8.1L engine in my home, but what I am wondering is if anyone has any good/ affordable solution to the issue? I'm not the most motor savvy, so I have reached out to other people on other cites for input too.. I've seen everything from welding them out, to replacing the whole works at a shop, to trying K.A.P bolt repair kits. Any suggestions or recommendations?

The easiet solution is probably using an Eazy-Out. First you drill a pilot hole in the broken bolt then put the Eazy-Out which is threaded left-handed, tap lightly with a hammer, then turn it with a wrench to remove the broken bolt.Get yourself replacement hardware from ARP, which has the best product for strength.

That sounds like a good option too. I just don't want the bolts to continue to break since we put on a lot of miles every year. I thought the concept of the KAP bolt repair kit was interesting as well because it is like a clamp/ bracket that holds the manifold together, rather than an extraction and replace method. I haven't looked into it a ton yet, but that and your suggestion are probably my best bets for handling it myself. Thanks!

It's somewhat easy to do but get a mechanic if you don't know what you're doing.

That KAP bolt repair kit looks like the way to go. Trying to get into there and drill out the bolts to use an EZ-Out looks like a real nightmare. And I've seen quite a few broken EZ-Outs over the years, and they create a real mess. Broken exhaust manifold bolts can be extremely stubborn to remove, and risk of breaking an EZ-Out is high. Not worth the hassle to me.

The OP suspects multiple broken bolts and would need a KAP kit for each bolt. Does it exist? Is the exhaust gasket still intact? I'm doubtful since red hot gasses could destroy it given the broken bolts. The exhaust manifold might be warped or need to be replaced. Sometimes there are updated parts to correct problems so this should be checked.Hopefully the KAP solution will solve the problem.

Broken/ leaking exhaust manifold bolts | Good Sam Community

CA_Traveler
Explorer III
May 14, 2019
The OP suspects multiple broken bolts and would need a KAP kit for each bolt. Does it exist?

Is the exhaust gasket still intact? I'm doubtful since red hot gasses could destroy it given the broken bolts. The exhaust manifold might be warped or need to be replaced. Sometimes there are updated parts to correct problems so this should be checked.

Hopefully the KAP solution will solve the problem.
fj12ryder
Explorer III
May 14, 2019
That KAP bolt repair kit looks like the way to go. Trying to get into there and drill out the bolts to use an EZ-Out looks like a real nightmare. And I've seen quite a few broken EZ-Outs over the years, and they create a real mess.

Broken exhaust manifold bolts can be extremely stubborn to remove, and risk of breaking an EZ-Out is high. Not worth the hassle to me.
azdryheat
Explorer
May 14, 2019
It's somewhat easy to do but get a mechanic if you don't know what you're doing.
teddy360
Explorer
May 14, 2019
That sounds like a good option too. I just don't want the bolts to continue to break since we put on a lot of miles every year. I thought the concept of the KAP bolt repair kit was interesting as well because it is like a clamp/ bracket that holds the manifold together, rather than an extraction and replace method. I haven't looked into it a ton yet, but that and your suggestion are probably my best bets for handling it myself. Thanks!
Gonzo42
Explorer
May 14, 2019
The easiet solution is probably using an Eazy-Out. First you drill a pilot hole in the broken bolt then put the Eazy-Out which is threaded left-handed, tap lightly with a hammer, then turn it with a wrench to remove the broken bolt.

Get yourself replacement hardware from ARP, which has the best product for strength.

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Broken/ leaking exhaust manifold bolts

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