Snapped Manifold bolts :(

[bmouthboyo]

Hello all, not a great day

I went out today to remove my old cracked manifold. Unfortunately the numpty who had last bolted it on used old worn nuts and as a result they slipped when in a 12mm socket, so i had to hammer on a 11mm.

This did the trick and 2 came out with a bit of persuasion, but was tight even after letting them soak for a few days in oil.

However 3 bolt heads snapped, 2 on the exhaust manifold and 1 on the intake manifold (was removing it to get to one of the most awquardly angled bolts ever).



Can anyone offer some advice on how to sort this? I know there are bolt extracting kits out there but not sure what kind i need for this or what kits you guys recommended.

Also what if it doesn't work? what then?

All your help is much appreciated thanks all.

[DarnPB]

Is the engine out of the car, or is the head off?? I see you are in Bournemouth. If you need a hand, P.M. me.

[bmouthboyo]

The head is still in the motor.

Its inside a T25 Camper, i noticed a crack in the manifold so been trying to get it off today when this happened.

[nealey]

it looks like there is still some stud sticking out of the head so if you get the manifold off you may be able to wind 2nuts on to the remainder of the stud and get the stud out that way

[Ben Lessani]

Dont faf about welding things on.

Go buy a set of stud extractors from Halfords (£20), you get 4 in a red metal box - but you do need about 4mm of visible thread.

[wil0]

I have used a couple of sets of stud extractor kits, the grabit type and some halfords ones. Both times they have snapped when trying to remove the bolts, and caused even more hassle. They are worth trying first though, especially if the bolts are quite big. soak them in penetrating oil first though, to try and free up the bolts first.
I always get some cutting compound, some sharp drill bits, drill a pilot hole initially really slow, then work your way just up to the size of the bolt and re-tap the thread. Keep applying more cutting compound and drill slowly and it gets there. Takes awhile, but i have ran out of stud extractors now.

[bmouthboyo]

The only problem i can see with that is the limited space down there as its in a T25 camper bay and its a bit tight.

My situation is this:

3 Broken bolts (so far) 2 in exhaust manifold and 1 in inlet manifold
2 bolts still on the exhaust manifold as i cannot get clearance to hammer a 11mm socket over them. Can grind one off but other has no room as inlet manifold is blocking access.

All inlet manifold bolts are off however one (seen in pic) snapped and as a result i don't seem to be able to pull the manifold off this broken one. I think maybe the top has bent when snapping and is blocking the manifold. I assume the manifold itself has no thread, so if a bolt snaps surly the manifold can just be pulled off of it then?

I basically need to get the inlet manifold off so i can get to the 2 remaining exhaust bolts. I think that all the snapped bolts so far will be protruding from the head a fair bit if i can get the manifolds themselves off. Then go in with some good mole grips.

Worst case scenario, how much am i looking at if i take the head complete with broken bolts in to an engineers for removal?

Hectic

[wil0]

If you can take the head off easily do it, it will be much easier than messing around in a confined space. Once its off, it will be easy to remove the studs or retap the holes.

[bmouthboyo]

Ideally i would like to not remove the head, but if it comes to that at least i have options.

Has anyone had any luck with removing snapped manifold bolts? If so how did you remove them with engine in situ??

On a side note i guess its not possible to heat the bolts up due to the head being aluminum?

Also would this be something a mobile mechanic would be able to sort? or would they not touch this?

thanks

[danny_p]

mobile mecanic would run a mile i bet i used to do a bit of it for extra beer money this is the sort of job u dread. 

gas is what you need  work the manifold off and then really heat the remaing bit of stud up get mole grips on it as tight as posible and work it loose.

tbh if i was doing it mobile i'd whip the head off  and do it on the bench in workshop  ( or more likely tell you that but call f**kit and grab another head )