Snapped an Exhaust Manifold Bolt

[CowPimp]

I snapped one of the 4 bolts holding the exhaust manifold tight against the turbo. It snapped about 1.5-2 inches down the bolt. Luckily, it has enough clamping force that no air is leaking around the gasket. However, I still want to replace the bolt.

How might I go about getting the rest of the bolt out of there? Probably no easy task.

 

[CanadianTSi]

If there is still enough of it sticking out then just grab it with some vice grips and twist it out.

If not then drill a hole in it and take it out with a easy out.

 

[CowPimp]

Hrm, so you're saying the bottom of the bolt sticks out a bit? That would be good.

 

[CowPimp]

Also, are there studs available that I could use in place of bolts? If so, can anyone direct me to a link. I checked out a couple of well-known DSM vendors and didn't find anything of the sort.

 

[oldman]

Also, are there studs available that I could use in place of bolts? If so, can anyone direct me to a link. I checked out a couple of well-known DSM vendors and didn't find anything of the sort.

You don't want to put any studs on there because it will make your future work harder. I'll give you one example, next time when you need to remove the exhaust manifold, you'll have to remove the turbo as well and vise versa. This is why most remove the original stud and replace it with a bolt the very first chance they get. The easiest thing for you is to remove the turbine housing via un-bolting it from the center section and take it to a machine shop as the turbo bolts are very hard to drill through. Good luck.

edit: Make sure you use anti-seize when re-install so this will not happen again.

 

[tranman91]

i had the same problem just a couple of weeks ago...

if you use an easy out...make sure it's of high quality and not some set you can pick up at schucks for $10...and drill your hole really straight.

the easy out i used ended up snapping off...and trying to drill that out...out of a broken stud was no joke...

after realizing that the housing was cracked inside anyways...i gave up and ordered a new one.

i was much happier spending $200 than dealing with that mess.