| From | Message |
bowhunter
Dodge Dakota
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5/14/2003
22:41:52
|
 Subject: manifold bolts
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Message:
I was wondering if anyone has had this problem, I
noticed that a manifold bolt has broken on my V6
(passenger side). After pulling off the heat shield and
manifold, the bolt was broken below the head. the guy
doing it then broke an "easy out" inside the broken bolt.
Now it's an expensive pain in the butt, since i'll have to
get the head taken off and go from there. Anyone else
have this problem?? the manifold bplts are these tiny
little 5/16 th x24 unf bolts.
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dodgeboy
Dodge Dakota
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5/15/2003
00:06:55
|  RE: manifold bolts
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Message:
very common problem! Had 2 studs on my friends 97 do the same. Took a few easyouts and a good bit of drilling with special hardened bits to get them out when installing headers. With the heads removed they may be able to get it out with a torch.
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Darren
Dodge Dakota
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5/15/2003
15:00:36
| RE: manifold bolts
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Message:
Seems more and more common. Any idea how much that costs to get those bolts drilled out, taken out, torched out, whatever? I need to do the same for my 1998 4x4. Not only is it an expensive (I am assuming) pain in the ass, that damn exhaust leak is really annoying.
thanks
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bowhunter
Dodge Dakota
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5/15/2003
19:17:16
|  RE: manifold bolts
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Message:
Darren: Providing you don't do like I did, and break an
easy out in them, they drill out fairly easy. Just make
sure you punch mark the broken stud as close to center
as you can. It is something you can do yourself, you will
need a right angle drill, due to space concerns. If you
took it to a good honest mechanic, it shouldn't be too
much. Mine made a racket, but when I put it back
together with the broken stud still in the head, and
tightened it all down, the noise went away. For how
long? I have no idea, but it is going into the shop next
week to be repaired by someone with better tools and
more patience than I. Will let you know the cost when
it's done.
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Darren
Dodge Dakota
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5/16/2003
15:46:28
| RE: manifold bolts
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Message:
Good information. Thanks Bowhunter. I will do just that. That is certainly good news. I have been holding off just for fear of what it would do to my checkbook.
Darren
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BurntOut
Dodge Dakota
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5/16/2003
16:22:50
| RE: manifold bolts
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Message:
In additional to bowhubter's post, look around and try to find letter "I" (.272") left handed drill bit. That is the drill size for a 5/16-24 tap. Most times as your drilling out the stud it will back out. If not, simply re-tap the hole after drilling to the correct depth.
Bill
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bowhunter
Dodge Dakota
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5/16/2003
18:51:38
| RE: manifold bolts
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Message:
burntout: bingo, that would be the easiest way, but
since not everyone is a machinist, i fiqured that for them
to find a letter drill would be hard enough, let alone a
left handed one. but excellent advice, and that would
certainly be the easiest way. just make sure to chase
the threads with a 5/16-24 tap.
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J and J Auto
Dodge Dakota
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5/16/2003
19:19:46
| RE: manifold bolts
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Message:
An honest shop should charge no more than half hour per hole to drill and tap.
However if you have an easyout broke off in the hole it needs to be broken out with a punch and takes longer or drill with a carbide drill.
What we do in our shop is drill them with a left
hand drill and they usualy unscrew as you step up
the drill size start small and center punch as
close to center as you can.
Pop the old manifold on and use a transfer punch.
We also do not charge for broken stud repair when
we install headers.
Larry
J&J Auto Service.
Wisconsin
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Tom Mize
Dodge Dakota
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6/04/2003
21:39:30
| RE: manifold bolts
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Message:
Man im learning more as i go along...ive got to do the same to my truck....hopefully soon...
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amish-psycho
Dodge Dakota
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6/05/2003
01:49:39
|  RE: manifold bolts
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Message:
I had this problem last weekend while changing head gaskets. One drilled and came out easily, the other was Satan reincarnate. Broke the extractor off. A couple of tips: Drill all the way through the broken bolt. Use lots of lubricant (LOL). Grind the broken bolt flush before punching and drilling. I spent 2 hrs. grinding out the broken extractor and getting it all fixed. I used a Dremel tool to grind away on the extractor and punched the rest of the broken part through. I anti-seized the crap out of the new hardware so next time won't be so tough. I also put on the gaskets that came with the Head gasket kit. Maybe that will be better than no gaskets at all. Good experiment though. ps don't trust you're Chilton/Haynes manual. Amish in AZ
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bdholsin
Dodge Dakota
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6/05/2003
12:30:15
| RE: manifold bolts
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Message:
dodgeboy - Where did you get the hardened bits to drill out the easyout?
I'm sure you can guess who did the same thing on his '97 3.9L Dakota. I ended up putting a gasket between the header and head then carefully tightening down the other three bolts. Incidentally - does anyone else find it interesting that the Dakota does not call out the need for a gasket at this interface? I found an aftermarket supplier and picked up a set (one for each bank).
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Remil
Dodge Dakota
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6/13/2003
05:02:52
| RE: manifold bolts
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Message:
I have the same problem and I have to get this thing fixed
before the end of the year so I can get it smogged. How
hard is it to unscrew the broken bolt out if a portion is still
sticking out. The broken stud on mine is flush with the
manifold, so if I take out the manifold theres gonna be
some of the broken stud sticking out.
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bowhunter
Dodge Dakota
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6/14/2003
15:16:07
| RE: manifold bolts
IP: Logged
Message:
Remil: if the stud is sticking out of the head, and not
below it, then it should be a piece of cake. just spray a
good penetrating oil on it, and let it sit for a bit, and grab
the remainder of the stud with a pair of vice grips, and
CAREFULLY turn it out.
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Sigma
Dodge Dakota
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6/15/2003
12:03:50
|  RE: manifold bolts
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Message:
Remil....I have found it to be easier to slip a larger dia nut over the broken stud & weld it. You can use a wrench & the heat from the welding loosens the stud....
I have even done this on studs broken off flush, but it is a gamble....Here I put a steel washer with the same dia of the stud with a nut over that stud..
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JamesRF
Dodge Dakota
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6/26/2003
20:14:21
| RE: manifold bolts
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Message:
Well guys it has to be a Dakota defect! I have a 98 2wd 3.9L and never pulled anything but my own weight. Had a radiator hose leak and went to fix it. Looked down and there was my heat shield with the manifold bolts attached, Two of the bolts just broke off in the head. This was on the driver side closest to the transmission. I removed the manifold and no gasket was used.
Well now I've really gone and done it trying to get the bolts out and an ease out broke off in one of the holes. Well I'll have to get a new head now I guess!! I have the remaining two bolts holding it on now along with some hose clamps to help reduce the tention untill I can get it repaired. Its a loud ticking noise now that I removed it and put it back on. Can anyone tell me if it will hurt to drive it like this for awhile? I need to make a trip 480 miles each way in a couple of weeks. I blame this all on Dodge. I'm sorry but this is something that should have never broken. I say its poor design. Looking at the way the exhaust is made it needs more support under the truck. The long spand of exhaust pipe under the truck goes from the driver side to passenger side with no support. Is there a recall on this?? Anyone ever get Dodge to pay for this?? My warrenty is expired but this should be a lifetime warrenty in my opion. Its become very costly to me.
James
j_r_fld@hotmail.com
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Dave Geiger
Dodge Dakota
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9/25/2003
12:51:26
| RE: manifold bolts
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Message:
I've got a 1999 dakota 2wd with two bolts on the passenger side of the manifold broken off. One is stuck in the heat shield the other is in the manifold. I could stick a straw about a 1/3 of the way in the hole before hitting the broken of bolt. I'm getting it fixed next weds. and will post how much it cost.
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NOSDART68
Dodge Dakota
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9/25/2003
23:12:19
| RE: manifold bolts
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Message:
My 92 has the same problem. Two of the driver's side bolts are broke flush in the head. I've been drivin it anyways, but it's getting unbearable! I'm gonna use the left hand drill bits and try to fix it. I'll let you know how it comes out.
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S. Hardy
Dodge Dakota
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9/25/2003
23:56:58
| RE: manifold bolts
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Message:
This is just a suggestion for all of you that are having problems.
Try PB Blaster, it is some amazing stuff, it will eat rust away like it's melting wax.
http://www.pbblaster.com/
Where I work maintance will use that stuff on everything and it frees up anything you put it on.
When you put your exhaust back on use anti-seize compound.
We also use that at work to put on die bolts. When we put the bolts in a jet cleaner at 1000 degrees at 25 inches of vacuum for 90 minutes, to clean the plastic and carbon off, the only thing still on them when there done is the anti-seize.
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Jon
Dodge Dakota
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9/26/2003
09:22:04
| RE: manifold bolts
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Message:
I have 1 stud broken off the front of each head, they were like that when i bought the truck but the manifolds never leaked. I put headers on my truck 2 months ago and i left the broken studs alone and so far i have no leaks. If i ever fix it i might just weld a new stud onto the end of the broken one instead of drilling it out.
-Jon
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Dave Geiger
Dodge Dakota
JOIN HERE
10/03/2003
15:38:55
|  RE: manifold bolts
IP: Logged
Message:
To conclude from my previous message, I spent $380 to have one bolt fixed. I'm pissed because the mechanic broke off an easy out. I guess I assumed he would use something else because I know not to use an easy out from reading all these messages. Needless to say they heated it up and then used a coil and that broke, they finally just drilled a new whole one size bigger. They didn't bother fixing the loose bolt on the heat shield. I'm just glad it was under $500. Also my upper ball joints are loose I was told.
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chris
Dodge Dakota
JOIN HERE
10/03/2003
23:14:21
| RE: manifold bolts
IP: Logged
Message:
I just experienced the same problem on my 98 Dakota w/3.9 finding the heat shield broken loose. The only problem is mine jammed in between the steering column and the upper ball joint. This just about locked up my steering. If I had not been on a straight road I'm sure I would have ended up in an accident. When I looked at the other side of the engine I found one of the two bolts already broken at the head. So now I'm having to drive around with no upper heat shields installed.
It looks like Dodge would have put out a Technical Service Bulletin by now with the number of complaints.
Chris
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