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start spraying the exhaust bolts with liquid wrench or some type of spray oil.. If they have never been off before or recently..more then likely they will break off..same as the flange bolts. The flange bolts you can just cut and redrill..the exhaust manifold bolts don't matter if they break if you plan on installing new heads.
All my exhaust manifold bolts snapped off..since they were metric and i couldnt get a metric bolt long enough at the Home Depot..I just bought new standard thread bolts, 5/16 i think it was, and a threader for them and rethreaded the exhaust manifold holes on the new head..made life easier. I also cut the two bolts on each side of the exhaust flange then drilled out the old threads and used new bolts/nuts.
I have also done heads on an "88 2.9. Just about all the exaust manifold bolts broke off so I had to drill them out and put in new threads as well. The stock metric bolts are only grade five hardness and twist like butter under stress if they don't break out first. Not even vice grips would take care of them after that, they just heated up and sheared closer again to the head, if I was able to tweak them at all. So if it looks like this for you, just twist out or break them off and drill them out to a new size or restore the original threads with those kits that are available. My left exaust manifold was miserable but the exaust pipe flange bolts turned out. The right....I just bought a brand new one on the cheap on EBay rather than mess with drilling out the old snapped bolts. I dont own a drill press. Seams the right one is a common problem for this reason and is commonly sold as a replacement for same reason as well.I didn't have the right tools so this saved me time and money. Good luck
There are two products that will help TREMENDOUSLY in keeping the exhaust manifold bolts from twisting and breaking so badly. One is PB Blaster (part number PB16); the other is Kroil from Kano Labs in Nashville, Tennessee. I have worked on Ford engines ever since 1966 and I have NEVER seen a solvent/penetrant to equal Kroil!
I also broke my exhaust manifold bolts off (3) i think, so plan on using some sort of never-seez when you replace them. I use a Marine Grade Never-Seez on all the bolts i replace.
make sure not to use the same gaskets i use pb blaster works great . never had a bolt break i just start spraying a day or two before i take them off. since your taking off the heads check the freeze plugs replace if needed check value orings replace if needed etc.. hope this helps
I just put new heads on my 87 Bronco II. Both heads were cracked, and the shop I use always takes a week to turn the heads around, and the fix was more than the price of new heads. I got two brand new heads, bolts, gasket set deiliverd to my door in 2 days for $430 from Alabama Cylinder Head. They have a .com with that name. The heads were $160 each. The only problem was the bracket bolts on the heads were oversized from the originals, so I had to put a larger bolt in the dip stick hold down for the tranny, the ground strap, and the AC brackets I think. ( I have a complete 88 that is my parts machine, but I don't remember what all I stole) . I got all new bolts at AutoZone for the exhaust manifolds. They had them behind the counter, not on the isle racks. The longer 100cm ones I got at Atwoods (farm store like Tractor Supply) The metrics are not to hard to find, I get them at ACE pretty often.
My exhaust bolts broke like glass!
Last edited by funnyfarmman; Oct 1, 2004 at 01:09 AM.