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imgreen
GenIII
 
5/08/2006
11:50:35
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 Subject: Broken Exhaust manifold bolt
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Message:
Was tuning up my 2000' Dak and found the heat shile on the drivers side exhaust manifold was loose. turns out the shield mount to the manifold bolts. One is broken off in the head. Anyone know a good way of removing the bolt with out removing the head?
If it ain't broke, your not trying!
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ftheabus
Dodge Dakota
JOIN HERE
5/08/2006
13:27:38
|  RE: Broken Exhaust manifold bolt
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Message:
I had to remove the head.
'00 3.9l 4x4 EC
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Chris
Dodge Dakota
JOIN HERE
5/11/2006
17:19:52
| RE: Broken Exhaust manifold bolt
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Two of the studs broke off the driver's side on my 93 3.9. I managed to drill them out with the manifold in place using a right angle drill motor and retap to the original diameter and thread pitch. I started with a smaller diameter drill, keeping it centered on the broken stud with a short length of metal tubing pushed into the manifold hole. Then I pulled the tubing out and took the hole up to the size (in steps) necessary to tap the threads. The rear-most one was a bit of a bear as it was kind of hidden by the brake booster. In both cases I had to use a mirror to see how it was going frequently between drill size changes. I also kept using a magnet to pull the shavings out. Patience is the key.
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J and J Auto
GenII
5/13/2006
22:57:58
| RE: Broken Exhaust manifold bolt
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Message:
leave the manifold on get a drill that just fits
the hole drill in slightly to get a good center
now remove the manifold have someone line you
straight use a couple lefthand drills step up
to the size most times it will catch on the
hole size drill turning backwards and screw out
than just run a tap in the hole and youe done
if you knew how many times this happend on header
instals these trucks come from the factory with
broke off bolts
a 90 degree drill also helps a straight drill
some times theres just no room some remove the
inner fender well to get a staright shot
Larry
J&J Auto
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zzark
*GenII*
5/14/2006
10:36:05
| RE: Broken Exhaust manifold bolt
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Message:
Larry,
What size are the bolts?
Are there special "manifold bolts" that should be used.
I have 2 broken bolts that I am afraid to tackle, but the ideas here sound good.
Thanks
zzark
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Obio3
Dodge Dakota
JOIN HERE
5/15/2006
04:35:50
| RE: Broken Exhaust manifold bolt
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Message:
far as I'm concerned, the 90 degree drill is a must. The job is half as hard to do no matter which bolts are broke off. So much easier to get leverage on the drill to speed things up and help the left handed bit catch. use split point cobalt drill bits also. another work/time saver.
So many problems .... So little time
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zzark
*GenII*
5/15/2006
08:56:33
| RE: Broken Exhaust manifold bolt
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Message:
When you say left-hand, are you talking about easy-out bits, or drill bits?
I've never seen left-handed drill bits.
What size bits?
Thanks
zzark
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DAHEMIKOTA
GenII
5/19/2006
03:08:37
| RE: Broken Exhaust manifold bolt
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Message:
About a year ago, there was a post about the same thing. Broken manifold bolts. I made mention to the individual that I manufactured a kit for removing broken bolts and studs from cylinder heads that did not require removing the head. It came with everything except the drill motor. The kit was priced at $30.00. Well Larry from J&J jumped in and said the kit was too complicated and you guys would not be able to use it. He never saw the kit so I can't figure how he knows it is too complicated. And I don't know how he can judge everyones mechanical abilities. My 10 year old grand daughter can use it with success. Not one person from this site inquired about the tool. Thanks Larry. If you are close to his shop, maybe he will repair your head for $30.00. Just had to vent.I don't sell them any more.
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zzark
*GenII*
5/19/2006
09:08:03
| RE: Broken Exhaust manifold bolt
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Message:
And 90 degree drills are hard to find.
I only saw 2, at over $200 each.
And I don't want a cordless.
zzark
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Obio3
Dodge Dakota
JOIN HERE
5/19/2006
11:42:56
| RE: Broken Exhaust manifold bolt
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Message:
Left handed bits are just as implied. they run counter clockwise or reverse of normal. and there everywhere on the net. Just type it in. They are so indespensible it's unreal. Any busted stud or bolt becomes a minor problem . Most turn out while your drilling. Myself I have a kit that has the cobalt bits and easy outs in one handy box so they don't get mixed with my regular bits. My reg bits are also cobalt. You can not believe how nice it is to use quality bits and they stay sharp 6 or 8 times longer then HSS . I also have a drill doctor 750. Nobody should be without one of these. So easy to use and I'm convinced it sharpens bits better then new. I'm talking super sharp.or angle drills, check out the referbished sites. better prices and myself I have better luck with referbished then new.
So many problems .... So little time
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shatto
Dodge Dakota
JOIN HERE
5/20/2006
18:14:26
| RE: Broken Exhaust manifold bolt
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Message:
Sears.
Might be on sale.
Check on-line.
Snap-On, Mac, etc. They supply the pro's.
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J and J Auto
GenII
5/20/2006
23:11:33
| RE: Broken Exhaust manifold bolt
IP: Logged
Message:
I never said anything about any kit I always tell
people to get left hand drills and start small
and step up
Auto parts store or hardware stors have left hand
drill they are same as reg drill just you must
run them in reverse rotation and most times they
catch turning counter clock wise and they screw
out not always than drill to size and tap
If they are broke off on the stock manifolds just
leave them it will not harm anything its when you
put the headers on you need all the bolts
Use quaility bolts grade 8 no elcheapos that break
off when tighting there are some very weak bolts
out there they are used for picnic tables not
for automotive use stay away from them for any
bolts you replace on your vehicle
Larry
J&J Auto
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J and J Auto
GenII
5/20/2006
23:21:33
| RE: Broken Exhaust manifold bolt
IP: Logged
Message:
one other thing be carful here I have had many
that came in with snaped off easy out than you
will need carbide drill to remove the tool steel
easy out a standard drill will not drill a easy
out
usualy the long shank easy outs the best ones I
have used were snap on they are short and right
in a 3/8 socket still most are not able to get
out with an easy out and must be drilled to tap
size and taped
I also had some destroyed so bad we removed the
head drill and install an incert not a heli coil
If you think you will have trouble find someone
who has experiance with this or it may end up
costing you more a couple hundred for a broken
stud would piss anyone off
On all the header instals I have done over the
years I never charged to drill a broken bolt but
if you bring me a destroyed head than your going
to pay for the repair mounting the head in the
milling machine carbide bits and end mills and
an incert takes time
Larry
J&J Auto
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zzark
*GenII*
5/21/2006
00:30:14
| RE: Broken Exhaust manifold bolt
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Message:
OK
Thanks to all.
I learn something new everyday.
zzark
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DAHEMIKOTA
GenII
5/21/2006
01:21:48
|  RE: Broken Exhaust manifold bolt
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Message:
Do a search on " broken,bolts" Look at item # 3. Just scroll through the posts. Dan
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entiland
Dodge Dakota
JOIN HERE
5/24/2006
12:35:10
|  larry your a great guy, but...
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Message:
Larry your advise and wisdom on this site is exceptional. I thank you many times over from reading your post, which have helped me out. I just have one request. Could you possibly use punctuation when posting? I have to read your post 3 times because I don't know where the sentences end. I'm not flaming you, I appreciate all of your advice. I just have trouble reading the posts. Thank you. MOPAR rules!!!!
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