Broken exhaust manifold bolts on 99 chevy 6.0L

[ec30_06]

So I decided to find my exhaust leak today. It turns out I have 4 broken exhaust manifold bolts. 3 on the drivers side and one on the passengers. Has anyone found the best way to get broken exhaust manifold bolts out of the heads on these trucks? # 7 looks to be the worst one to get at. I would rather not pull the head off if I don't have to. All but one look like they are flush with the head. Any Idea what a shop would charge for this if I don't feel like doing it?

[Scott K]

A shop will charge you actual time to drill them out and retap if necessary. Most shops in your area are $100 plus per hour, I would think 5-6 hours max

[Whoaru99]

Any Idea what a shop would charge for this if I don't feel like doing it?

How much you got?

Sorry...don't have more specific advice. Hope that small bit of intended humor helps a little.

[Scott K]

If you decide to do it yourself, and like doing it, I have 4 busted on my f150 you can do as well

[LMITOUT]

Originally Posted By: ec30_06

Any Idea what a shop would charge for this if I don't feel like doing it?

How much you got?

[Big Buck Buster]

If you do it yourself, you can take the inner fender wells out to gain more access to the manifolds for easier removal. Takes a little time to get the inner fender wells out, but worth it in the long run. Much easier to work with with them out of the way.

[Macgyver55]

Unfortunately I've had the (dis)pleasure of doing probably 100 of these. I used to drill them and use an easy out, but after drilling one crooked and messing up threads and helicoils and headaches I decided to try this. What I do now, and it has worked every time since for me, is to remove the manifold, take a new 9/16 nut, hold it over the broken stud and give it a quick zap in the middle with the wirefeed. When cool, put on a socket and turn it out. They are not usually very tight, as they snap off not twist off. I have done the entire job in less than an hour. Make sure to replace them all with new bolts.

[Big Buck Buster]

Unfortunately I've had the (dis)pleasure of doing probably 100 of these. I used to drill them and use an easy out, but after drilling one crooked and messing up threads and helicoils and headaches I decided to try this. What I do now, and it has worked every time since for me, is to remove the manifold, take a new 9/16 nut, hold it over the broken stud and give it a quick zap in the middle with the wirefeed. When cool, put on a socket and turn it out. They are not usually very tight, as they snap off not twist off. I have done the entire job in less than an hour. Make sure to replace them all with new bolts.

I have done this many times on them, and works very well. The only vehicle that it didn't work on was a trailblazer. That was not fun with the back bolt breaking off. Ended up making a short drill bit for that job. Drilling and heli coiling that one.

[Whoaru99]

If they're not rusted in and generally not tight, how about a reverse-twist drill bit?

[ec30_06]

I'm going to try the wire feed trick first, and then left hand drill bits with an angle drill second.

[deadeye]

The wire feed would be the best bet. Don't be afraid to try it a couple times either. The bigger nut you can use the better too. That's what we did way back in the day when I worked part time at the exhaust shop.

[CAMAN]

Be sure to chase the threads with the correct size tap before reinstalling the bolts.