Exhaust Mainfold - Snapped Bolt - Help!

[tdutzi]

I own a 1992 jeep Cherokee Laredo and have attempted to replace the exhaust as it was rusted out and falling off the car. Unfortunately I had to remove the exhaust pipe from the exhaust manifold and in the process I snapped the lower bolt on the exhaust manifold. Luckily I was able to remove the nut on the upper bolt without a problem.



My question is what I should do with the lower bolt. I tried to tap it out with a hammer but it is attached to the exhaust manifold rather solidly. Do you know if the bolt is pressed into place on the stock manifold, or in my case is it probably just rusted in rather firmly. I have been using PB Blaster very liberally but it has not helped (except when I removed the nut from the upper bolt). Should I try to hammer it out or do I risk damaging the rest of the manifold? Should I try to cut the bolt off flush with the manifold and then tap out the rest of the bolt with a punch? Do you think this is possible to do working on it from under the car.



I have attached some pictures of the exhaust manifold Any suggestions would be appreciated.

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[Griemster1]

Your best bet and easiest way in my opion is to cut it down flush and then drill out remaning bold in down pip and just replace with your own bolt and washer.

 

[tdutzi]

Hey, thanks for the feedback. Luckily I was able to pop out the bolt as I found it was only pressed in. I used a balljoint puller. Basically the tool looks like a c clamp except there is a hole on the far end that I slid over the bolt head. As you tighten the shaft on the bolt, it just pushes the bolt out through the hole. Currently the new exhaust is installed and operating well.

 

[jnaut]

Hey, thanks for the feedback. Luckily I was able to pop out the bolt as I found it was only pressed in. I used a balljoint puller. Basically the tool looks like a c clamp except there is a hole on the far end that I slid over the bolt head. As you tighten the shaft on the bolt, it just pushes the bolt out through the hole. Currently the new exhaust is installed and operating well.

Glad to hear it. -- for future situations though, there are some serious 'penetrants' out there that you would not believe. A wrench turner friend of mind discovered something that a GM dealer sold-- I can't remember the stuff, but he said it actually had a GM part number. I didn't believe him how well the stuff worked, so he told me to bring in anything I could find that was completely fused together. I found a bold arrangement I had sitting around the garage from a license plate holder that I had to break off to switch my plates. Anyhoo, it was a nut on a bolt that was a ball of corrosion and rust... a lot like the picture you showed. We put it in a small dish over night, and when I came back in the next day the nut and bolt were clean and the nut could be unscrewed right off.

 

[tdutzi]

That is awsome. I am going to research and see if I can find that penatrant!

 

[Dave]

tdutzi.....Glad you got that bolt out.

jnaut.......see if you can find out what that rusted bolt remover stuff was. I am curious what works the best. I usually use that PBBlaster stuff.

Dave

 

[jnaut]

tdutzi.....Glad you got that bolt out.

jnaut.......see if you can find out what that rusted bolt remover stuff was. I am curious what works the best. I usually use that PBBlaster stuff.

Dave

I'll try. I'm not in contact with that guy anymore, but I'll see if I can find it. I will tell you that he was told about it by a friend, went to a GM parts counter, and started telling the parts guy about it, and said he thought it had a gm part number, and the guy pulled the can out from behind the counter and said "This stuff?" and that was the stuff. I seem to recall that it wasn't in a spray can like a lot of penetrants are, but that just may be my failing memory.

Dave, I just found this PDF: http://www.edelbrock.com/automotive_new/misc/tech_center/install/6000/67152.pdf

It lists a GM penetrant part number GM #1052627. I'm wondering if that's it.

 

[Dave]

Dave, I just found this PDF: http://www.edelbrock.com/automotive_new/misc/tech_center/install/6000/67152.pdf

It lists a GM penetrant part number GM #1052627. I'm wondering if that's it.

jnaut....thanks, I will check it out. It's funny that they list that penetrant and right after it they list antisieze.......haha.....I guess I am easily amused.

Dave