Major Mess...2.9 Heads!!!

fenix1 · #1 (**permalink**) 04-15-2008, 07:43 AM

Tore down 2.9 to swap heads. Went to take Exhaust Manifold bolts out. Some "NUT" managed to "Round" the heads off of bout half the bolts on each side! Going to have to pull the heads with the manifolds connected and then grind the bolt heads off. Question is: How do you manage to get the bolts out of the Manifolds from the Crossover pipe??? Looks like to me Ford probably jammed that engine in there with the crossover already bolted on! Ya can't get to the bolts from underneath and I can't see how in HELL ya can even get to em' from above!!! Any suggestions would really be appreciated cause I'm bout to "pull my hair out" messin' with this thing!!!

TheHandyman · #2 (**permalink**) 05-09-2008, 10:57 AM

Cut the exhaust pipes off, then weld them back later.

8588ranger · #3 (**permalink**) 05-12-2008, 01:17 AM

If it's the bolts that hold the crossover pipes on to the exhaust manifold that you're talking about, I used a 15mm 6 point 1/2 drive socket with a long enough extention.
And don't round them out, other wise you will have more problems. Your local Ford dealer has new ones.
And as for the exhaust manifold bolts their is to snap and break.

fenix1 · #4 (**permalink**) 05-17-2008, 07:46 AM

Well, managed to break the Crossover Pipe Bolt heads off and pulled the heads off with the Exhaust Manifold intact, took my Craftsman Broken Bolt Head remover and got the Exh.Man. Bolts out. Had to drill the Crossover out. ANYWAYS, couldn't find any replacement bolts nearby, finally called the nearest Ford Dealer bout 20 miles away. Almost had a coronary when they told me the Exh.Man Bolts were $246 including Tax! I didn't even ask what the Flange Bolts cost. The parts lady was nice enought to tell me the Size, Pitch, and Length of them since there were 3 different lengths. Got on the phone and called a Hardware Supply place in Shreveport(LA) bout 75 miles north of here. When I told the partsman what I needed and he told me they would all be $ 30 I told him, "Ill be there in an hour and a half!!! Same Bolts(Heat Treated)Savings...probably $300 after gas and a Burger w/ fries. Something to think about when it comes to Fasteners.

Kruse · #5 (**permalink**) 05-17-2008, 01:40 PM

Quote:

Originally Posted by fenix1

Almost had a coronary when they told me the Exh.Man Bolts were $246 including Tax!

I replaced the fuel pump on my Dodge Dakota pickup a few weeks ago. I ordered a few replacement parts over the phone from the Dodge dealer. I think there was a few rubber grommets, the tank straps and a couple of bolts that hold the straps to the frame. The two bolts that held the straps to the frame were 3/8" X 3" (or something very similar in length) and were not even zinc plated. They were just regular bolts that you could pick up at any hardware store and I believe they were grade 5. The dealer charged me $17 each for these bolts! I had my wife pick up all the parts from the dealer so I didn't realize what these costs until I saw the ticket.
Needless to say, I took them back. Talk about a corporation being greedy. I know they got to make a little money, but give me a break.