So i took my exhaust manifolds off about a year ago, and i broke 2 bolts on the top manifold on driver side. i was woundering how i would go about taking these out, only the head part broke. there is still the threads on the bolt sticking out.

if at all possible, i would like to do this myself.
thank you for your time.

 

With a torch and some vise grips it can be done. You need to be careful as you don't want to burn the truck to the ground(if it has any kind of oil leaks).

If you can heat the ear up quickly, then give it a spurt of PB Blaster you can get the studs out. The opening in the back of the hole allows rust to build up and like you found will make the bolts break.

If the broken piece is too short, then you'll have to drill it out. Either with hand drill while on the truck, or remove head and do it(or have shop do it).

I had one years back and since it was in the back and hard to get to I just wallered out the hole and used a nut/bolt to hold the header(or manifold in your case). It worked fine for the last few years I drove the truck.

 

If only the head snapped off, I'd weld a nut to the stud. Then apply heat or maybe even freeze it with a shot of Loctite's "Freeze N Release" (in a can!!).

http://www.loctitefreezeandrelease.com/

 

Like said above be careful with fire. Removing these will need to take some patients.
If at all possible if you have a hand wheel die grinder cut off any threads on the back side of the bolt boss ear. These rusted threads will be the biggest problem for removing the stud. Heat them up red hot then put ice cube to fast chill down. (Note) do not spray any type of BPor wd40 while it's hot or you'll have a fire right quick. Then put vise-gripes on and only do short back and fourth movements slowly working it out. Try to keep the vise-grips locked in one place and not chew up the stud. As you have it turning some the area maybe cool enough to now use the lube or wax candle will also help lube the threads. Point as long as you can work the stud out. I've tried using freeze stuff but found ice cube chill was free verses $4-5 bucks for a can.
Also tapping on the broken stud head with a hammer helps loosen up rusted threads too. So doing everything here and above should get them out..
orich

 

okay, so i got one of the bolts out, the other bolt snapped if inside the threaded part of the head. so now i have a bolt that i cannot get out. again. its the very back top bolt on drivers side. what do i do to get it out with out taking the head off the motor? or is that the only thing i can do?
i dont have much room at all to work with, maybe around 6 inches. would taking my steering and all that out help? or would it be to much work?
i really want to get this done so i can put some headers on it.

 

codafisler, Every thing orich said is right on the money, I had a Stern drive repair shop for 35 years and dealt with my share of frozen and broken bolts. On the last bolt try this trick to drill it out correctly. Remount the manifold with all the bolts, Snap -on sells a hardend drill guide kit that will center the drill bit. Or maybe borrow one. You only have one chance to drill it straight. Obtain a new 3/8 x16 starting tap and using tap oil very, very carefully rethread the drilled hole after drilling it to 5/16 which is the recommended size for 3/8 16. The chances of extracting a bolt like this usually ends up with a broken extractor in the hole. Since the hole in the manifold is larger try to center it as much as possible. Stacking a few gaskets under the manifold should locate the the center of the bolt. Removing the steering should give enough room, also unbolting the left motor mount and raising the engine up may help. Good Luck Kenny Nunez

 

Hmm boy your putting us old guys through the memory test. Well let me ask you what were you thinking just before it snapped. If it was anything like maybe, I should stop and run it back in case it's getting to tight or work it just back & forth some more. Most guys will not stop and just go for it and continue on the way out. This is when we should listen to the little voice that says better Stop which they don't and the stud snaps. Well if any of this crossed your mind then you have learned a important lesson for removing frozen or broken studs...If you had it coming out when it then broke your easiest way now maybe is to run it back out the other way. But you'll have to do like the OP says and drill it all the way out through to the other side. The more you can drill of the inner part of this stud the out better. I know this is not ez to do. I'd use a short length of copper1/4" tubing maybe 2'' long as a hole drill guide with a 1/4" drill bit inside the tubing. This is for centering your pilot hole to drill all the way through the stud. Push the tube into the stud hole and hold it into place while drilling it. Once you've got this done you just keep drilling it out to the next size drill bit. Then stop if your going to drill into the boss threads. Now heat the inner part of the threads the best you can. Now use your largest ez out from the back side all with care not to repeat how you got to this point. And when it comes out pat yourself on the back...my 2cents oh maybe 3cents now...orich