Broken/ leaking exhaust manifold bolts

[teddy360]

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?

[theoldwizard1]

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

ABSOLUTELY !

I have been a "shade tree" mechanic for almost 50 years, and replacing an exhaust manifold and studs/bolts is something I would never attempt (except in my broke/stupid youth) !

If it means driving for a couple of more weeks while you save up the money, it will be worth it !!

[Matt_Colie]

Teddy,

This repair is a sure way to end up in more trouble than you had before. If there is a KAP that will do the job, go that way, but its long term survival is doubtful.

We do not know anything about your rig and we don't need to for this. But, if you as an inexperienced person try to remove the failed fastener, I give you about a snowball's chance of making things better.

A big part of the problem is that with the engine in the rig, there is very limited room to work. People that do this every day have both experience and a bunch of learned cheap tricks that can make a big difference.

What ever happens, put everything back together with low grade fasteners (SAE gr 2) and slather it all with nickel base anti-sieze. That is because you will be taking it apart again and alloy fasteners do not like the temperature of exhaust things.

Matt

[schlep1967]

Unless you have a good deal of experience, this is a job for a professional. An easy out may work but it will most likely take a lot of heat on that area to have any chance. Those bolt heads broke off for a reason. The bolts are rusted into the holes and you are very likely to break off the easy out. Once that happens and you now have a hardened chunk of steel in the middle of the soft bolt you need to get drilled out, the professional is going to cost even more.

[Dave_H_M]

X3 here on the easy out. If you go there once, that will be the first time and last on what to do next after the easy out snaps :h

[ZINGERLITE]

I just used a couple clamps on my half ton with a 5.3. Can't speak for how they'll hold up over time but my exhaust leak is fixed.

It seems like a halfass fix but it works and i don't need to take the head off.

[T18skyguy]

They do sell jigs that keep a drill straight for that application, but sorry I can't remember the name. Once you get them out, go with Banks headers if you can afford it, or Thorley headers are also good and not as expensive. If the manifold is warped greater than .01 inch no gasket will seal it. If your going to keep the rig, then headers are a good way to go.

[CA_Traveler]

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]

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]

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

[teddy360]

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]

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.