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Anonymous Posted on Jul 12, 2012

Big mistake, drilling out broken manifold bolt on exhaust and drilled to far into water jacket. How do I fix this

What have I done and what damage did I cause. I am looking for ideas on how to fix.

  • Anonymous Jul 13, 2012

    Does anybody have any ideas?

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1 Answer

Marvin

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  • Chevrolet Master 85,242 Answers
  • Posted on Jul 13, 2012
Marvin
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Seal the threads of the new bolt with loctite brand thread sealer, it is available from most auto parts stores. Don't worry many engine have bolts that go into the water jacket by design.

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Exhaust manifold bolt broke off into head, is there anything I can use to temporary fix it.

no temporary fix
the real fix is to remove the manifold , drill and use an extractor tool to remove the broken stud
however if the stud is at the end of the manifold , consider this
many exhaust manifolds do not use a stud at the ends
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How to remove a broken bolt the easy way...

Say you have snapped the head off a rusty bolt on the car, its infuriating!

But, there is a fantastic tip from a mechanical engineer that works every time, and is easy to do!

Lets assume the bolt is a 10mm exhaust stud or similar, take a 4mm drill bit (sharp one) and a 4mm hex (allen) key, (especially a t-bar type or socket mounted one) - drill a pilot hole right down into the bolt with the 4mm drill, as far as you can without snapping the drill bit in the bolt!!! Use light pressure, a sharp drill bit and let the drill do the work, and keep it straight....then when you pull the drill out, tap the hex key into the hole you made with a hammer, get it in as far as you can, it will be a tight fit as the 4mm hex key measures 4mm from flat to flat across it, and the corners of each flat are slightly more than that so it bites very well into the bolt, spray plenty of release fluid or wd40 around the exposed bolt thread to help loosen it, leave for 10 minutes if rusty, then turn the hex key with either a socket and wrench or the t-handle on it, and it will turn the bolt without slipping!

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