DD15, snapped exhaust manifold bolts

Fix it right, or fix it twice.

 

When it comes to drilling broken bolts out of expensive engines all bets are off and I charge by the hour. It takes skill and expertise with quality tools to be done correctly without causing further damage to the engine. Some fall out with a left handed bit in 10 minutes when everything goes smooth. Others take 2 hours or longer per bolt.

All components will need to be removed to repair broken exhaust manifold bolts broken off flush in the cylinder head. Even if you could get the broken bolts out and replaced, it would likely still be leaking when you got done.

 

If you don't know what you are doing, take it to the shop. The peace of mind in work that is guaranteed in case there is a hiccup is worth the extra money. One thing I'll tell you is don't put off repairs. "It's been like that for a while" is a good way to keep you down for extended periods of time, instead of taking the time and money to do it once and do it right. Don't let problems fester into something greater.

Good luck.

 

or even fix it thrice.

 

I've gone to great lengths on them. Weld the center of a washer to the broken bolt. Then weld a nut to the washer. Back out with impact.

This is the best way, and my most successful way to me. I have had it not work. I've drilled some, I've went as far as grinding them out with Dremel and carbide bit.

Good luck.

 

Exhaust work tends to go 1 of 2 ways.

Either the bolt comes out with no trouble (rare) or its locked in there (usually how it goes) and you're sitting there, working the bolt back and forth for an hour or 2 so you don't damage the manifold stud holes in the head.

Its cheaper for the customer for the mechanic to take their time so as to avoid damaging the head (or snapping off an extractor in the broken bolt, at which point you're up #### creek).

 

Carbide eats extractors also. But your in for a long day.

 

And several dozen metal splinters all over your body