Exaust bolts snapped...

[Jamie Miles]

I recently put a '71 200 in my '69 1/2 Maverick. Engine has 30,000 original miles, but the exaust manifold is cracked in half. While removeing it, 4 bolts snapped off. I tried my hardest not to snap them off, but to no avail...

Two of them snapped off flush with the block, the other two have about one inch nubs sticking out. Hopeing I can just grab those two with vice grips and get them out.

How can I get the other two out? The very front most top bolt and very rear most rear bolt are the two that snapped off flush.

 

[woodbutcher]

I have seen broken bolts and studs respond nicely to reverse rotation drill bits.Of course,you need to use a drill that is variable speed and reversible.The heat generated from the drill bit will usually loosen the bolt and will screw out with the bit.Use some type of lube on the bit when drilling.These types of bit come in sets.
Leo

 

[Jamie Miles]

Intresting. Do you think I could achieve the same results by drilling from the top with a standard rotation drill bit? The two that are broke off flush are the last bolts in the top on either end of the head, so I actually have access to the back side of the bolts. I'm trying to avoid pulling the head or destroying the threads.

In hindsight, I wish I would have dealt with this before putting the engine in the car!

 

[addo]

Use a right angled drill adapter if lacking in room, and reverse drill bits. Otherwise, you're raising the stakes higher.

 

[Anonymous]

They are usually so rusted even a left handed bit won't help.

I actually center-punched mine and tapped to 5/16". I figured the rest of the bolt was WELDED into the head and wouldn't move, and I was right. It worked perfectly.

 

[nachoman]

i hate it when this happens. All I can say is an easy out - but if the easy out breaks off in the hole you are really SOL. use the largest easy out you can.

I can suggest replacing the bolts with stainless steel bolts. I replaced all of my manifold bolts with stainless steel except one (just forgot to buy one), and this weekend when I had to take the manifold off, the only bolt I had prolems with was the non-stainless one.

taking the head off is not that bad of a job - don't rule that out because in the long run it may be quicker if it means easier. I was working with some water well drillers a few weeks ago, and they had some drill pipe break in two about 1200 feet down. Something like 20,000 lbs of pipe and a drill bit had to be grabbed onto and pulled to the surface. They brought out the biggest easy out I ever saw - and that didn't work. Eventually they got something down there to grip to the outside of the pipe and got it free.

kevin

 

[Anonymous]

They brought out the biggest easy out I ever saw - they got something down there to grip to the outside of the pipe and got it free.

Drillers have cool toys!
I have seen oil driller crews go down and bring stuff back up that was a lot deeper than that!

 

[Jamie Miles]

taking the head off is not that bad of a job - don't rule that out because in the long run it may be quicker if it means easier.

I know. I've had the head off my 250 a few times. This 200 I just didn't want to touch since it's such low mileage. But if I have to, I have to...

 

[Anonymous]

drill and tap the outer 2. (or drill and bolt thru)

use the studs and put a header on it.

kinda redneck, but it worked for me!

 

[Jamie Miles]

(or drill and bolt thru)

You know what? I just had one of those "DUH!" moments. Why worry about the threads when I can just put a bolt directly through... Why did I not think of that?

 

[fordconvert]

If its just those two end bolts they should be fairly easy to heat them up even with one of those crappy propane/oxy torches you can buy at a hardware store. Those ears are pretty small so they should heat easily... or were those the ones that broke off flush....

Heat works great but if its on the main part of the head you will need a little more power to get them hot enough to do any good.

 

[Anonymous]

I just had one of those "DUH!" moments. Why worry about the threads when I can just put a bolt directly through... Why did I not think of that?

Maybe its because you don't read. I mentioned drilling through 6 posts up.

 

[Junk-Falcon]

ppp