broken bolt removal

[Zorm]

Ok, removed my exhaust manifold on the 200 because of an exhaust leak, broken front bolt ear (top). While I was removing the manifold, I noticed that one of the bolt holes was missing the bolt. Once I removed the manifold, I found out why, broken bolt. :x
So, what is the best way to remove a bolt from the exhaust side of the head? The bolt is the top rear one in the middle, where the manifild connects to the pipe. There is about 1/4" tapering down to 1/8" of the bolt sticking out. I thought about spraying in some PB Blaster and trying to grip it with a pair if Vise-grips but don't really want to risk destroying the bolt to where I can't get a grip on it, nor do I want to mar the gasket seating area too bad,
Any ideas welcome!

 

[Anonymous]

The vise grip way may work if there is enough of a stub above the hole opening and its not too tight. Use a torch to heat up the area should help.

The other ways would be to use a reverse drill bit, which would grab the bolt and spin it right out. Grind down the stub above the surface flush so mas to make sure the bit is easily centered. Just be careful and make sure you do not drill it off center and damage the threads.

The other way would be, and this is only the last resort and if the bolt wont come out with the previous steps, to drill it out and unsert a helicoil repair insert.

 

[Zorm]

I'll need to try the heat way, the engine is still in the car so space is limited and I don't think I will be able to get a drill in there.
thanks

 

[rickwrench]

Don't use an easy-out. If you have acces to a mig welder weld a big washer or short bolt to th exposed piece. Let it get nice and molten, after it cools it will come right out
Rick(wrench)

 

[addo]

If you are at all underconfident, remove the head and get professional hep with this bolt. It beats making a mess in-situ. Knowing when to farm out work, is sometimes a tough issue and can bring the more stubborn of us, unstuck!

Cheers, Adam.

 

[S2261]

I agree with Adam. If you break it off you'll need to remove the head anyway. You could wrestle with it in the car. It is hard to get at and may not come out easily. You could spend the same amount of time removing the head dropping it off at a machine shop, and putting the head back on.

 

[Anonymous]

There are better things than easy outs- one I have found is a splined shaft that is hit into a hole drilled into the bolt and an internally splined nut is slid over the shaft. A ring spanner or socket is then used to apply twisting force to remove the broken bolt. A toolstore should have them. Easy outs are s..t-they are too brittle and break leaving you stranded-these others actually torque up and release for better bolt removal and don't break.
If this won't work, it's the more aggressive method or head removal and use of a metal disintegrator that is required. This last method uses an arc to erode the broken bolt.
PS: tap on the broken bolt with a punch to release some of the tightening torque- it can sometimes help- then try bolt removal techniques.

 

[Anonymous]

I had a guy come in and do mine.Did a great job,threads were good,no damage.When I started,I did not have a clue how to find someone but went to the dealership and got a number for a guy who does thiss on a regular basis.
The dealerships in your area will probably be able to help you with a name because most contract this kind of work out.
It cost me about 50 bucks to do.

Ponyman