1997 F350 Crew Manifold/Header Swap

[gentrykm]

Hello everyone,
Ok here it is. I have a 97 f350 with a 460. In the process of swapping the stock manifolds for headers I have run into a few issues. I was looking for some help. Here are the problems:
1. The very back bolt passenger side appears to not have ever had a head on it or it was broken by the previous owner. Do I remove it? How?
2. The second to last bolt passenger side broke off with about an 1/8th inch protruding from the head. How do I remove that one?
3. The EGR tube inlet angle fitting into the old driver's side manifold broke off. How/can I fab a new one maybe utilizing some high temp tubing to hook up with the EGR tube? Or do I/how do I get a plate made to block it off?
4. The second from front spark plug passenger side broke off and all of the ceramic is gone leaving a hollowed out half of plug. How do I get it out without removing the head?
5. Nobody I know had the common decency to kick me in the nuts for attempting this project knowing my tendency to break half of whatever I am working on.
As you can probably tell the driver side went much better than the passenger side as I have been able to install that header without major difficulty. Any help that anyone can supply would be greatly appreciated. Thanks, Kenny

[gentrykm]

Anybody? I am gettin into this weekend and have to finish can anyone help me? Thanks, Kenny

[gentrykm]

WOW! Thanks everybody the response has been so overwhelming I don't know whose idea I will try first. Thanks for nothin

[jimdandy]

What would you want us to say? There is no magic formula/method for removing broken bolts/plugs. You may have to remove the heads, none of us are there looking at the engine. On old engines that have not been touched, this is bound to happen, especially with anything having to do with the edxhaust manifolds. You had apparently already broken everything off before coming here for help, so don't get upset that we can't be of assistance. jd

[gentrykm]

All I was looking for were some ideas, not a magic formula. Through investigation around these forums I have found some of the dumbest questions and even dumber answers. So I guess I thought I had some valid questions and was looking for some previous experience of someone else to aid in the problems. So in other words jimdandy, bite me

[bad96]

from my experience ya generally need to take the head off, that way you can use an easy out, drill out and tap, or there is a tool that will grab broken bolts(similar to a pipe wrench)but they can re-break

but the problem is theres usually not enough room to use these tools in the engine compartment especially with a 460

good luck!!!!!!!!!!

[gentrykm]

Thanks so much bad96. I got lucky and managed to get the plug out with an easy out and some heat. But after working on the two bolts now for 4 hours (actually just one of them) I am no better off on that front then I was, but I refuse to give up and if I must remove the head I suppose I will and pray I dont bust those bolts. Anyways thanks a lot I was beginning to wonder if I would ever get any ideas from someone maybe more experienced than myself.

[kens64]

Either spray some PB Blaster and let it sit overnight or use some heat. That and a sharp hit with a hammer can break one loose.

Thats all I ever use.

[Bear River]

If you have a lot of tools at your disposal, you can extract the broken studs and bolts. PB blaster can work wonders, and a good set of visegrips can turn almost anything that can be turned. If that fails, you will probably have to pull the head and take it to a machine shop. Head bolts are much harder to break, just work slowly, and use impact to help loosen them. Impact is less likely to break the bolts than constant torque. If you have a good air compressor, I really do recommend an air powered impact gun, if not, you can buy a 1/2" drive electric one, though they are not as good. Its probably not worth it if this is the only job you will need it for, and in that case, just hit the wrench with a rubber mallet and be careful not to round off the heads. Use the closed end of the wrench as much as possible.

[gentrykm]

Thanks Bear I am gettin ready to get back at it now so we'll see how it goes.

[gentrykm]

Well I got one broken bolt out today with some help from the welder and a pipe wrench. Tomorrow I was thinking I would fab some kind of jig to help me drill out the other one since there is nothing sticking out to grab on to. I hope I dont screw it up by puncturing a water jacket or something. So we'll see how it goes. I am determined to leave the head in place to save a big headache. Off I go. Thanks guys

[Bear River]

I would be very careful about drilling it out. You are dealing with a hardened steel bolt which is hard to drill, in a soft aluminum head. The bit will likely try to wander off the bolt and into the aluminum if you are not careful.

[gentrykm]

I thought I would make a jig out of a half inch piece of steel with 3 holes in it that line up with the bolt holes on the head and bolt it on to the head through the the 2 outside holes and leave the center empty to drill through. I thought that would keep the bit from walking.

[gentrykm]

Do you know where I can find out what size the holes are and which tap I should use to clean out the hole?

[dkf]

Do a search up in the V10 forum, there are tons of threads on removing broken studs. Heres a link to one http://www.ford-trucks.com/forums/59...ud-or-two.html

How to remove broken studs depends somewhat on if the studs are broken off flush to the head or are sticking out some. If they are sticking out you may be able to get a vise grips on and turn the stud out. If they are broken of flush you can use a left handed drill and an eze out to remove them. Some studs may need to be drilled out completely and a helicoil installed. I don't forsee you having to remove the head.