cant get rustly bolts out need some tips... (exhaust manifold swap)

[Jason84]

well i got the heat shield off.. i cant get the 4 turbo bolts to even crack loose. its a wisconsin car (yes rust love) and i put some wd40 on it.. (also did this last weekend when i had it all apart) and they wont even crack loose. i also tried hitting the ratchet with a small sledge hammer to try and jerk em loose that didnt work. i also tried to hit em a tad tighter and that didnt work. so i cant get the 3 bolts and 1 nut off need some tips here !!

i also tried using some penetrating fluid my dad got me from his work. which he calls "jesus juice" and gets anything out.


how long should i let the fluids sit till i try to remove it ?


*edit*

also do i really need to keep them heat shields infront of the exhaust manifold and the turbo ?? the exhaust manifold one is rusted the heck. the one infront of the turbo just has some rust spots on it.

if i dont need it... where can i reroute that o2 sensor wire ?

 

[Desibabu345]

I think your best bet is to get a dremel or hack saw of some sort and cut off the bolts, that way you can buy new ones (rust free) and yea the heat shield is good it helps keep the exhaust gas temps high = faster flow. But thats for a non turbo maybe for a turbo its different?

 

[Jason84]

i already have all new bolts and studs for it. but they are just OEM replacements i got from dsmotor sports.

 

[Generation X]

Originally posted by Jason84
i already have all new bolts and studs for it. but they are just OEM replacements i got from dsmotor sports.

I had to use a breaker bar to get mine loose. I couldn't apply enough torque by just using a regular ratchet. Be prepared, they make a loud pop type sound when ever you do finally break them loose.

 

[allwheelTSI]

soak them once a day in PB or liquid wrench for about 3 days. mine came out with barely any effort after that.

 

[hose101772]

If the car runs,start it up and get the exhaust to full temp.Shut off engine and let cool.As its cooling down,say 20 mins or so,try it then.Heat will usually get them to break loose.Torch will be fine if it doent run.Another thing to try is hitting the bolts-not the stud-dead on top with a hammer a few times,this can help break loose the death grip those develope.

 

[Dans91Tsi]

Use a torch to heat up the bolts very very hot, and use candle wax in the end of the threads. The candle wax losens up the threads and lubes them. Makes it easy.

 

[jbillakdsm]

The candle method helps, but PB Blaster or Aerokroil will work deep down in the threads. If you decide to use a torch, aim the flame away from the bolt and try to heat around the bolt only. Use a breaker bar and a socket from an impact set. I broke 3 Craftsman and 1 Snap-On regular sockets trying to get mine off before I busted out the impact wrench set.

When you go to replace your hardware DO NOT use the stud again. It's probably has internal cracks from being there so long and you'll want to murder someone if you put it all back together and it breaks tightening down the new nut. Once you have it out of the car, pull the turbo apart and resoak the other end of the stud and work on pulling it. Redrill it if necessary and get a larger bolt. Mine came out fairly easy after being soaked numberous times while trying to get everything else apart. Replace it with another bolt so you don't have to pull the exhaust manifold next time your turbo needs to come off.

 

[dave99gst]

once ya heet it up -- it should be fairly easy to break loose.. running the car is the easyest method. Once there out use some anti-sieze on the threads to make it easyer next time .

 

[Dans91Tsi]

Dont use antiseize buy copper bolts and you'll have no problem.

 

[Dans91Tsi]

Dont use antiseize buy copper bolts and you'll have no problem.

 

[mephist0]

where do you get the copper bolts?????

 

[Generation X]

Originally posted by Dans91Tsi
Dont use antiseize buy copper bolts and you'll have no problem.

Is the tensil strength on the copper bolts as strong as the automotive grade metal bolts?

 

[jbillakdsm]

Originally posted by Generation X
Is the tensil strength on the copper bolts as strong as the automotive grade metal bolts?

No

 

[Dans91Tsi]

Im not sure about the tensile strength on the bolts. But its strong enough for exhaust. Ive used it before with no problem. I read about it in a super Chevy magizine a while back.

 

[LSupreemo]

Originally posted by Dans91Tsi
Im not sure about the tensile strength on the bolts. But its strong enough for exhaust. Ive used it before with no problem. I read about it in a super Chevy magizine a while back.

The strongest way is steel bolts/studs and bronze nuts -- that's how
Alfa Romeo and Maserati used to do it. Call around to Italian
mechanics. A good bronze nut will have an outer size bigger
than usual for its thread size -- because it's not as strong.

 

[markGSX]

Slip a 1 foot metal pipe over the end of your socket wrench handle, and BAM there you go.

 

[Generation X]

I just took my exhaust manifold off because of a crack, and noticed the nuts that hold it on with are copper, or atleast they look copper in color.