header install annoyance

[taman86]

Started to do my short header swap yesterday. Started yesterday afternoon and GOT stopped in the evening because I started to install the driver side and when I got to putting in the bolts I noticed that the upper forward most bolt hole was filled in, and I thought to myself, no freaking way. I started looking at all the stud bolts since all 4 corners of the manifold had the studs and low and behold a broken bolt. I found it odd because I soaked the bolts with pb blaster, and warmed them up and they were all coming out no problem. When I inspected the broken bolt the center is rusted not a fresh break and clean metal so that tells me that it's been open for a while. So today I get to try extract a broken bolt in my head that wasn't my fault.

 

[Arth]

These trucks are notorious for breaking those header bolts.

My 2009 Ram had one broken as well.

Usually when one breaks you will get a loud clicking or ticking sound on cold start up that goes away when the engine is warm.

 

[charonblk07]

Yup, broken head studs were bad enough that dodge released a tsb and a hardened replacement bolt for it.


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[bouf0010]

Or just slap the stock manifolds on and drive it to the dealership

 

[taman86]

Spent the day trying to get that broken bolt out. Had to go buy a rechargeable mini screw driver and hex drive titanium bits. I'm pretty close to being deep enough to get an extractor in there. Just a pain in the tight space and all the crap in the way on the driver side. I would've been done yesterday if it weren't for that broken bolt. As for the tick on startup never noticed it and not even a trace of a leak on the old gasket either. I'll finish it up tomorrow.

 

[taman86]

Well wasn't able to get that broken bolt out but I used copper rtv on the gasket on the head and manifold side and made sure the two bolts next to it work good n tight and it sealed. Gotta love the headers. I have to say other then the broken bolt this was one of my tougher header installs.

 

[LovMyRam]

Well wasn't able to get that broken bolt out but I used copper rtv on the gasket on the head and manifold side and made sure the two bolts next to it work good n tight and it sealed. Gotta love the headers. I have to say other then the broken bolt this was one of my tougher header installs.

A bandaid at best, you'll regret it down the road. Fix it right the first time. It may take a while, but you'll see.

 

[powderbrad]

^^ I concur. No matter how much of a PITA it is, its even more PITA a second time.

 

[jcat]

EZ outs are cheap and easy to use. Just get it done right and skip worrying about it later

 

[BlownGP]

I think a few on mine or broken. Not sure though....

I never had the tick, but one day going to work It sounded like I had a huge exhaust leak. When I started my truck to go home, I was going to check it out. Sounded normal and hasn't made that noise sense.. SO I dunno.

 

[taman86]

Yaaaaa easy outs didn't work. The angle I was working at wasn't working very well and it kicked off the bolt and started to drill into the head. I am going to have to helicoil it to repair it when and if it leaks. As of right now it's not.

 

[charonblk07]

Just curious, you did remove the inner fender shroud to get better access, right? And were you trying to drill it out with the new header on or off?

 

[taman86]

Yes and off

 

[xrsman]

Yes and off

How's It sound now? Have you noticed a difference in power yet?

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[taman86]

Definitely sounds aggressive with magnaflow muffler high flow merge and resonators removed. Power isn't huge gain by itself but noticeable and responsive