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Mike Stager
Dodge Dakota
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9/17/2006
01:26:41
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 Subject: broken exhaust bolts
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Message:
The front 2 exhaust bolts are sheered off on the passenger side of my truck, and I was wondering what success anyone has had/thinks I'll have by drilling and removing the broken studs with the heads on the truck. With the inner fenderwell removed, I've got plenty of access to them. I'm going to have to take the manifold off to do it as it's shifted off center due to the exhaust pipe pulling on the back of the manifold, so it's tilted up in front. I was hoping for a straight shot so I could use the manifold as a bit of a guide for drilling.
Any advice? If it comes down to it, I'll pull the heads off and take them to a shop, but I'm not afraid to attempt it with a good drill bit, an easy out and a tap ( already have the right size tap )
I'm not familiar enough with the truck yet to know what kind of metals they've used for the bolts. If the exhaust bolts are relatively soft, then I'll certainly give it a go with the heads on considering the fact that they are cast iron, but I'd rather get a solid set of opinions before I potentially take the truck down for a couple of days.
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Obio3
Dodge Dakota
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9/17/2006
02:06:13
| RE: broken exhaust bolts
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Couple of things here first. Buy some grade 8 replacement bolts/studs and nuts. Replace ALL THE BOLTS both sides of the engine cause there going to keep right on breaking. This way you do the job one time. You really need a reversable angle drill. Also Left handed cobalt drill bits and the easy outs. Thing is as you keep working up to bigger drill bits with the left handed bits, the stud most likely will turn out while drilling. Don't forget to use good rust buster on the bolts. You can find a nice set of cobalt bits/easy outs in a set for 29.00 bucks on the internet. They will do a great job and stay sharp a long long time. IF YOU USE CUTTING OIL on them frequently they will stay sharp a lot longer.
So many problems .... So little time
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zzark
*GenII*
9/17/2006
10:59:08
| RE: broken exhaust bolts
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Message:
I had one stud on each side that I tried to remove.
I read all about it on this board.
I bought left-handed drill bits and a right angle drill.
I was doing good with the drilling.
Then I tried the easy-outs and broke them in each hole.
That's when I gave up and took it to a shop.
They had to remove the heads. Cost under $900.
So, good luck.
zzark
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Mike Stager
Dodge Dakota
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9/18/2006
01:23:34
| RE: broken exhaust bolts
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Message:
Buyer beware I guess.
Well, I have a small torch set so I've got something to heat the bolts up a little if I need to to get things loosened up.
I've learned that you can't force a bolt to loosen up, it will break.
I guess I'm more concerned about the two remaining bolts and getting them out without breaking them off in the event that I have to bolt the manifold back on and drive it for a while longer until I have the time to pull the heads off and have them done proper if the need comes.
Any advice in that dept? Those long thin bolts...I don't trust them. And I will be replacing the bolts with better grade bolts/studs and making sure to use an anti-seize compound on them. Seems the bolt design they used is poor.
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J and J Auto
GenII
9/22/2006
23:36:37
| RE: broken exhaust bolts
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Message:
You don't want to heat that with a torch you may
crack the head NO NO cast iron
leave the manifold on use a drill that just fits
drill into the stude just slightly this will get
you a good center
trying to center punch this stud is almost
imposible
have someone line you straight and step up in size
if you have to drill to tap size and tap left hand
drills run drill in rev.
The best esyouts to use are made by snapon they
are short and mounted in a socket the long
easyouts break very easy
If they do not screw out while drilling with left
hand drill and easyout is not going to do it
I have seen heads so bad with easyout broke of
drilled way to big we had to put incerts in not
heli coils but thread incerts
Larry
J&J Auto
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Brendan
Dodge Dakota
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9/24/2006
22:22:49
| RE: broken exhaust bolts
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The front 2 bolts on the drivers side of my truck broke off. I recieved many pieces of advice. I do all my work but am not ashamed to say that I took it to my local Dodge dealer. Cost me 403.00 but their was no stress due to broken bits, bolts, or easy outs. Sometimes you need to know when to call in reinforcements.
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OBIO3
Dodge Dakota
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9/24/2006
22:59:22
| RE: broken exhaust bolts
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Message:
The biggest problem with easyouts is instlling them way to tight. Once you drill the broken bolt it is thin metal and to put the easyout in tight expands the bolt so tight you break the easyout. Doing it like Larry says is the best way by far. gets you centered as good as possible plus after making a good dent to start a small bit dead center you can work your way up to the point the bolt is very thin and weak. It should back out with the drill running in reverce. This all depends on taking your time and doing things right. The price of the tools is far far less then a repair shop.
So many problems .... So little time
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ES
Dodge Dakota
JOIN HERE
9/25/2006
21:36:28
| RE: broken exhaust bolts
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Message:
Another trick i learned with bigger bolts not sure if it may work for your application, but as a last ditch effort after the holes have been drilled etc... break out the die grinder or the dremel with a very small bit and just grind from the center out on 2 opposing sides as thin as u can with out messing up the threads. Then try a screw driver or take a punch and tap the pieces into each other splitting the bolt in 2 or atleast bending the bolt enough to take the stress off where u can unthread it with a screw driver or dig the 2 chunks out.
Ive even had some studs so stuck that i had to cut them into 4 chunks to get them out.
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