mechanics help needed

sliverslinger · 12-31-2006, 08:03 AM

Guys, I need some help. I am swapping motors and everything was going great until I got to the exhaust manifolds. On my truck they came off nice and easy. On the other one though, On one side I got 3 of them out ok but I broke off the other 3. There is a nub sticking out where it broke off. I still have to do the other side, but I think at least a few are going to break. They are rusted in, I have already soaked them for 2 days with penetrating oil. Once I get them off, How do I get the nubs out? Heat? a couple of nuts? Please help. Thank you in advance.

Fshklr · 12-31-2006, 08:08 AM

Quote:

Originally Posted by sliverslinger2001

Guys, I need some help. I am swapping motors and everything was going great until I got to the exhaust manifolds. On my truck they came off nice and easy. On the other one though, On one side I got 3 of them out ok but I broke off the other 3. There is a nub sticking out where it broke off. I still have to do the other side, but I think at least a few are going to break. They are rusted in, I have already soaked them for 2 days with penetrating oil. Once I get them off, How do I get the nubs out? Heat? a couple of nuts? Please help. Thank you in advance.

3 options...
1st: vice grip and HEAT(torch/portable propane bottle and attachment)...don't try more than twice per nub, don't get it red hot..just some heat to break it free.

BESURE not to have GAS, OIL, or other flamables within the area...have appropriate fire extinguisher ready

2nd: head to parts store and get a drill bit and "Easy Out" for the recommended size of the nub and threads.

3rd: drill it out and re-tap

I would suggest 1 and 2...# 3 can be dangerous and disasterous if you are not skilled with the process.

nativedipper · 12-31-2006, 10:15 AM

Do NOT heat if you are going to try to drill. By heating it you will harden the stud and make it very hard to drill. If you still have the some of the stud sticking out where you can get a good hold on it and don't have room for a drill go ahead and heat it. Then wait for it to cool before you try to take it out with vise grips. If you have a welder you can weld a nut on it also.

The Chub · 12-31-2006, 10:30 AM

Put it all back together and take it to a exhaust shop. Too many things can go wrong if you try to do it yourself.

johndeeregreen · 12-31-2006, 10:39 AM

It sounds like the motor is out and in that case this is what I have done and it worked for me.
Take a small drill and drill length wise down the broken bolt to the other end. It sould not be bottemed out and you can tell when it is through.Then spray PB Blaster in that hole so it is getting oil from the other end of the bolt and then pean the studd a few times with a ballpean hammer. DON'T get in a hurry.

EULACHON · 12-31-2006, 02:26 PM

There is some stuff called PB Blaster we used it on the bolts on Turbine Helicopters (get VERY HOT) and it was the best stuff, WAY BETTER then WD and liquid wrench.

Worth a shot let me know if you need some I think I have a couple cans

Paul

johndeeregreen · 12-31-2006, 02:37 PM

Hands down you can't beat PB Blaster.......

Gundog · 12-31-2006, 03:04 PM

Take the manifold and weld nuts on the nubs they will come right out I promise. If they break off inside use an arc welder put the elctrode on the end of broken stud or bolt carefully turn on machine with the electrode in contact with the bolt so it sticks then shut off machine it will probably come out by hand afterwards.

These methods are much easier than drilling and trying to get it out with an easy out and if this fails you still have that option break off an easy out and your options are almost nill.

If you don't have a welder bring by the manifolds and I will do it.
GD

suckerfish · 12-31-2006, 04:43 PM

Quote:

Originally Posted by Gundog

Take the manifold and weld nuts on the nubs they will come right out I promise. If they break off inside use an arc welder put the elctrode on the end of broken stud or bolt carefully turn on machine with the electrode in contact with the bolt so it sticks then shut off machine it will probably come out by hand afterwards.

These methods are much easier than drilling and trying to get it out with an easy out and if this fails you still have that option break off an easy out and your options are almost nill.

If you don't have a welder bring by the manifolds and I will do it.
GD

This is how I would do this too. However, if you don't have a welder, put some heat around the broken bolt. Get it hot, then take a regular candle and the melting wax will leach into the threads. might have to continue to put some heat on the area until the wax is taken in. Then just put some vise grips on the nubs or weld a nut to them. They will come out.

suckerfish

sliverslinger · 12-31-2006, 04:59 PM

They are stuck in the head part of the motor. I am going to try the 2 nut method. if that fails, I will then be open to options. There is about 1" hanging out on most of them But I thnk I broke a coouple of them off flush to the heads.

IDWITHELD · 12-31-2006, 04:59 PM

Yup, weld nut onto studs.

1pump · 12-31-2006, 05:13 PM

You can always take the cylinder heads off and take them to a machine shop if all else fails. They're a lot easier to drill out on a drill press.

When the studs broke on my 351W I used Alden Drill-Outs to try to back them out. The studs were stuck too bad for the drill-outs to handle, but the bit cutter did a nice job of drilling the studs out without buggering up the threads.

Easy-outs are a joke. They're neither easy nor do they get anything out. Break one off, and you'll be hatin' life.

The Chub · 12-31-2006, 05:35 PM

Quote:

Originally Posted by 1pump

Easy-outs are a joke.

Yes they are.

sunshinefisherman · 01-01-2007, 07:25 PM

There is a device called a Heli Coil that replaces the original crappy threads with a new stainless steel thread. The kit comes with a special drill bit, a special tap, an installation tool and several inserts.
Us a smaller pilot drill to drill through the old bolt and then use the heli coil bit for the final diameter. You then tap the hole to the new size and screw in the insert. It works like a charm and the threads are superior to the original. Most threads in castings suck anyway but Heli Coils never come out and never strip or rust.

Your manifold bolts are probably 3/8-16 or a similar metric equivalent. The kits in these smaller sizes are not too expensive but the larger sizes like 5/8" sparkplugs and the like can run into some change.

You can see what I'm talking about on this webpage

http://www.mcmaster.com/ goto page #3096