Exhaust Bolt Broke

mike101010 · August 11, 2011

i have a 04 6.0L and the infamous manifold bolt broke on it. of coure its on the driver side most rear one.i brought it to a dealer and they quoted me 2300 bucks to fix it.said they had to pull the head and send it to a machine shop HOW PATHETIC IS THAT. so my question is has anyone been able to get the stud out without pulling the head.this one is broken flush with the head.i was thinking of taking the manifold off and just welding a nut to it to get it off.if i do this will just unplugging the battery be ok or am i going to fry the computers and who knows what else from welding on the engine.

if i do get the bolt out what should i use to replace the bolts i've been reading on here the new bolts from gm do the same thing.anyone tried a grade 8 bolt?

gregrocks89 · August 13, 2011

I heard grade 8 bolts work well but id like to know more about this though. Cause i got a 04 6litre as well and i gotta change my exhaust gaskets out sometime. Ive never had a bolt break off in the past with other trucks.

mike101010 · August 13, 2011

i dont know really why they break on the ls engines its all of them from the 4.8 to the 6.0.for what ever reason the head breaks off the bolt over time and the bolts are locktited in from the factory and from what i read a bear to get out.i looked at mine closer and both the passenger and driver side rear most bolts are broke and has exhaust leak.im guessing im going to have no choice but to pull the heads im alittle leary on welding a nut to it.dont want to cook my computers.with my luck im sure the other bolts will break when i try to take the manifold off.

gregrocks89 · August 13, 2011

I hear ya on the exhaust leaks. I got one on each side of the block. I havent gotten around to an actual inspection to see exactly where but the sound seems to coming from the exhaust manifold itself.

Carder09 · August 14, 2011

Though welding is an option, maybe try JB weld, I've used it in some auto repair and it seemed to work until I was able to replace the item.

GPSilverado · August 14, 2011

i have a 04 6.0L and the infamous manifold bolt broke on it. of coure its on the driver side most rear one.i brought it to a dealer and they quoted me 2300 bucks to fix it.said they had to pull the head and send it to a machine shop HOW PATHETIC IS THAT. so my question is has anyone been able to get the stud out without pulling the head.this one is broken flush with the head.i was thinking of taking the manifold off and just welding a nut to it to get it off.if i do this will just unplugging the battery be ok or am i going to fry the computers and who knows what else from welding on the engine.
if i do get the bolt out what should i use to replace the bolts i've been reading on here the new bolts from gm do the same thing.anyone tried a grade 8 bolt?

Sounds like it might be worth checking the price of remanufactured heads (complete) before paying the dealership that much. Then again, if you could pull them yourself, you would save a ton of money.

Broken exhaust bolts are one of the hardest things to deal with. If someone tries to drill them out, they should have the heads off the vehicle. If you try it with them on, there is almost no chance of drilling the center of the bolt, and keeping it straight. If you get off center, you can ruin the chance of getting a new bolt in correctly.

Welding a nut onto it is an idea I hadn't thought of. My worry would be what happens if the bolt still doesn't come loose. Either it breaks off deeper or you have to grind the nut back off?

mike101010 · August 14, 2011

im more worried about welding on the engine and blowing computers than it breaking again.welding it and then heating it up with a torch it should come out.mine is already broke flush with the head so it wont break any further.has anyone ever tried welding a nut to it?

yukon25008.1 · August 14, 2011

Im having the same problem with an 05 sierra with 8.1 and its the last bolt back on the drivers side, Im now shooping for a set of shortys or lt,s . Im definitly not gonna pull the heads though..way to much work to fix an exhaust leak..if you start with a good bit the old bolt should drill right out then youcan pick and choose your tap aand new bolt size.

Ive also had good luck with epoxy..but dont think it will be strong enough to back the old/broken bolt out..

Please let us know how you make out.

old dog · August 14, 2011

yeah i have the same one broke on my 01 2500hd 6.0 , i found out about a local shop that has a fixture to hold centered in the manifold bolt hole that allow's them to drill out the bolt and remove it with out pulling the head and sending it to a machine shop .they have to pull the fenderwell on that side to get some room to work but i am going to go for it ,got to before winter .

Im having the same problem with an 05 sierra with 8.1 and its the last bolt back on the drivers side, Im now shooping for a set of shortys or lt,s . Im definitly not gonna pull the heads though..way to much work to fix an exhaust leak..if you start with a good bit the old bolt should drill right out then you can pick and choose your tap aand new bolt size.
Ive also had good luck with epoxy..but dont think it will be strong enough to back the old/broken bolt out..

Please let us know how you make out.

blacksierra01 · August 14, 2011

Most broken or twisted off maifold bolts that I have encountered have been siezed in the manifold itself. I usually take an air hammer and bust the old maifold all up, then the bolts usually turn out easily. no need to remove the head.Not sure how much a exhaust mani goes for but its still going to be cheaper than pulling a head.

mike101010 · August 15, 2011

the manifold is fine the bolts break on there own

Gone Again · August 15, 2011

Maybe there's something here you can use.

http://www.google.com/search?sourceid=navc...n+manifold+bolt

gregrocks89 · August 16, 2011

i just went and finally looked to see where my leak was coming from. yup my exhaust manifolds are fubar. One is broke in two on the one side and its warped and the other is warped to.

tanked_darren · August 17, 2011

Yo, I know this trick if you want to weld a nut to it. Try welding a washer first, then a nut, it will be stronger. Millwright experience.

hrspwr · August 17, 2011

What an oldschool welder taught me to do when bolts have broken flush is I get a washer the same diameter as the bolt and weld that to the bolt. Next get a nut that is a bit larger then the bolt, but smaller then the outside diameter of the washer and weld that on. The heat from the weld will cause the bolt to free up, and the nut you welded will give you something to turn it out. Has worked for me everytime. Best to use a MIG welder for this.

Just read that Darren said the same thing lol.