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Busted Exhaust Mainfold Bolts..?

Bulldog13

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Sep 20, 2007
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:(...Daughter going off to college next week...she's got a 2001 Isuzu Rodeo 2.2liter 4 cylinder..used to belong to her grandpa...he paid about 1500 bucks a few years back for a full exhaust..it started to get noisey and when I checked it out I noticied the front 2 studs were broken off in the block.Is this a hell of a job?..I was gonna try and heat em up and back em out with visegrips ...school starts next tuesday ...should I wait till we can get it to the garage???
 
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gahrajmahal

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Dec 12, 2008
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Cincinnati, Ohio
The fact they are the front 2 studs makes it a better job. i would go through the trouble of removing the manifold as its probably warped and needs to be sanded flat. Take it to the auto parts machine shop for an A1 resurfacing job, or if you are a gear head, just get out your belt sander and finish it up with a flat file. I have heard that heating them up and applying a little candle wax will allow them to come out. I have never been that lucky, they always snap off close to the block so I have had to drill them out and use an ez-out. That you can get at the auto parts store. Good luck!
 
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Bulldog13

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These are pretty rusty, I'm not sure what the candle wax will do , but thanks for the idea.I'd like to avoid drilling them out as its pretty tight in the engine bay...I'm sure the manifold's gonna have to come out..but I don't want to break more bolts in the process.
 

sberry

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Jun 18, 2005
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Acetone and auto trans fluid is the best but I usually weld a flat washer, then a nut on. Removed 8 of them last week. I rarely drill a bolt out.
 

nissan_crawler

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Wichita, KS
Acetone and auto trans fluid is the best but I usually weld a flat washer, then a nut on. Removed 8 of them last week. I rarely drill a bolt out.

x2 on this if it works. I had some I couldn't do that way. I ended up taking some 3/4" plate and drilling it to match the exhaust manifold, sliding it on the remaining studs, and using it as a guide to drill out the broken ones.
 
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sberry

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I did some the other day and have one on my desk, did the washer and grind a little slot in it for a screwdriver, they were in aluminum head and actually had to build them out a little before I could weld washer on, nice and toasty and they come right out. I believe this pic was on an old Cadillac head. Exhaust manifold I think.
 

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dakota_522

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Aug 26, 2009
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49
that looks like its working if it was me i would try to find a junk yard or just replace it because its proly wraped. and i would replace the O2 sensor the old one thats in there will never read right and it will bad gas milage.i just had the same problem on my truck i replaced the mainfold and put a new O2 sensor in there, its so quite now and gets great gas milage.
 
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Bulldog13

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FYI....my daughter actually got the bolts taken care of...a kid from the neighborhood goes to the local Voc-tech school, he offered to take the car in and have it done by the students...its gonna cost me a total of about 75bucks.Well worth it,wasn't looking forward to drilling them bolts out...
 
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Bulldog13

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Not sure...materials ...probally new studs whatever...beats 75 bucks a hour at the local shop...Hell I'm gonna send over a few pizzas after...saves me time and money..
 
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