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rusted exhaust manifold bolts... what can i do

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Old 06-07-2008, 12:42 PM   #1
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rusted exhaust manifold bolts... what can i do

i am doing a head job on my 96 s-10 (4.3l) and cannot get to the outside head bolts because of the exhaust manifolds... the bolts are so rusted the nut is a round shape.

i thought i could cut it but can't get my grinder in there to get a clean swipe.

Is there anything i can use or do to get these manifolds off???
Old 06-07-2008, 01:28 PM   #2
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Re: rusted exhaust manifold bolts... what can i do

Go to sears and the get the BOLT OUT kit , runs bout $20 or so . But it works better than anything , even on round headed bolts . You will use it over and over again
Old 06-07-2008, 04:05 PM   #3
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Re: rusted exhaust manifold bolts... what can i do

Cut them off, like with a sawzall then when the manifold slides off, you have plenty to grab onto with a vice grips.
Old 06-07-2008, 05:41 PM   #4
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Re: rusted exhaust manifold bolts... what can i do

A small Dremel with a 1.25" cut off wheel will get into some pretty tight spaces. I was surprised at how fast that sucker would cut a bolt head off!
Old 06-08-2008, 01:09 PM   #5
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Re: rusted exhaust manifold bolts... what can i do

Make sure you get the fiberglass cutoff dremel wheels. The stone ones wear out too quick.
Old 06-10-2008, 01:42 PM   #6
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Re: rusted exhaust manifold bolts... what can i do

I'm going to give the multi-tool a try... i never had much luck with it... seen it as more of a hobby tool

i'll let you guys know
Old 06-10-2008, 01:43 PM   #7
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Re: rusted exhaust manifold bolts... what can i do

Also i forgot to mention that it was the bottom side of the manifold where it attaches to the "y" pipe that i have to cut off
Old 06-10-2008, 01:55 PM   #8
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Re: rusted exhaust manifold bolts... what can i do

You know, it only takes about ~an hour or so to take the fender and fender well off. Then you can just drill the cap off and it makes it a lot easier installing the head.
Just a thought!
Old 06-15-2008, 01:46 PM   #9
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Re: rusted exhaust manifold bolts... what can i do

With the inner fenders off i still can't get a good angle at the bolts with my grinder...

i'm down to two options from what i can see...

cut the pipe right below the oxygen sensor, that way i can have a straight pipe and hopefully pull it out the front... then reconnect when everything is ok... (will I have room to pull the manifold out forward? and how close can i get to the oxygen sensor without fowling it?)

or ...

give up haha...

let me know if there are any other ideas...
Old 06-15-2008, 04:25 PM   #10
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Re: rusted exhaust manifold bolts... what can i do

Tellin you that the bolt out kit will work the best , it works with a ratchet and will work wonders no matter how rounded the head is , I have used it on many exhaust systems
Old 06-15-2008, 04:26 PM   #11
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Re: rusted exhaust manifold bolts... what can i do

ALso if you just cut them off then you have the same problem trying to get the rest of the bolt out
Old 06-15-2008, 04:34 PM   #12
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Re: rusted exhaust manifold bolts... what can i do

Quote: Originally Posted by Project89
Tellin you that the bolt out kit will work the best , it works with a ratchet and will work wonders no matter how rounded the head is , I have used it on many exhaust systems

x2!!!

Those things are indispensable in my toolbox
Old 06-15-2008, 07:13 PM   #13
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Re: rusted exhaust manifold bolts... what can i do

Can you post a picture so we can get a better idea of
what you're facing ? Maybe then we can come up with
a game plan.
Old 06-15-2008, 10:00 PM   #14
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Re: rusted exhaust manifold bolts... what can i do

you could use a torch to heat up the nut, then use the bolt out thing the other guy was talking about to get them out. you could use one of those benzene torches if you dont have access to an oxy/cetelene torch.
Old 06-15-2008, 10:25 PM   #15
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Re: rusted exhaust manifold bolts... what can i do

If you have the fender off check to see if you can drill the head of the bolt off. We usually start with a small bit to drill a pilot hole then a bigger bit..
Try not to go any deeper than you have too.
After you pull the head, the machine shop will be able to pull and replace the bolt.
Pain in the ass.
Good luck.
Old 06-15-2008, 10:30 PM   #16
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Re: rusted exhaust manifold bolts... what can i do

you talking about the 3 bolt downpipe flange? BLEH, cut them off behind the flange, youll have 1/2 inch or more to get them out when you have the manifolds off.
Old 06-16-2008, 01:21 AM   #17
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Re: rusted exhaust manifold bolts... what can i do

+1 on the bolt out kit, those things work magic on stripped bolt heads and even studs. I picked up one a few months back and god knows how many times its helped me out. I'd pick up a kit and heat the area and try and back it off, it will more then likely come right out.
Old 06-16-2008, 06:31 AM   #18
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Re: rusted exhaust manifold bolts... what can i do

One more thing , instead of heat , go get a can of PB BLASTER , spray it on there and let it sit a few minutes , then use bolt out .
I have used the PB BLASTER many times on bolts that where rusted in there and man it eats that crap away and loosens the bolt right up . Can get it at Advance , auto zone , walmart , dollar store bout anywhere
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