Is there any secret to removing the exhaust manifolds without breaking the studs off in the head...these studs and nuts seem really tight...do they always break?...whats your experience?...do you usually get the exhaust manifolds off without breaking a stud??...any help would be great..

 

I ended up breaking all but two on my truck even after soaking them in PB Buster for a week. Helicoils for everyone!


Im sure others will chime in. But soaking them is a good place to start.

 

Soak them for a week and when the time comes to finally remove them, get the engine warm for removal. I soaked mine for 3 weeks with PB blaster then when the day came to change them I took a quick loop of the neighborhood, pulled into the driveway where I had tools ready, threw on some leather gloves and went for it. Yes the manifolds were hot, but I got all of them cracked loose and backed out several turns without breaking a single one. Then I waited a little bit for things to cool down and went out to finish the job. Didn't break a single bolt.

 

Run the motor until it starts to warm up, spray the studs with PB blaster. Do this every day for at least a week before you remove them. Warming the motor up before you spray it makes the PB blaster act like solder and run into the threads. Otherwise, do what Evan said.

 

what happens if you do break one...how expensive is it for a machine shop to fix the head??...and thanks for the tips....I will try pb blaster and heat..

 

try breaking loose by tightening, after all the above said treatments.


if they gon' break, they gon' break....be prepared to let the truck sit for a week when youre ready to tackle the job that way you don't have any surprises. i.e. removing the heads in the event one does break.

 

Soak the hell outta them.

When you put a wrench on the bolt just turn it a tad then go back… then turn it a little then go back. Do that while soaking them AGAIN with your favorite rust penetrant. Be very patient and you will minimize breakage. Just a little wiggle… don't go all Chuck Norris on 'em and you'll be OK.

 

I am about to give this a try on my recently acquired '87 f250. Fortunately for me, some of the bolts are already out! (and probably laying on the road somewhere near the PO's house.

 

You don't necessarily have to pull the heads to fix the snapped bolt. I went drilled them out and helicoiled them while still in the truck. Going through the wheel well helps.