exaust manifold bolts

[redram77]

So, my 2004 ram with a hemi has an exaust manifold leak.
upon inspection I see that the heads of the manifold bolts have rusted off enough to allow the manifold to slip over top of them causing them to leak.
now I know that this has been an issue for some. I am dreading tearing into it as I know the bolts are most likely to shear off when I try to take them out to replace them. a steel bolt into an aluminum head is going to cause problems.
So, I am wondering if others have tackeled this job and if anyone has any tips to avoid shearing the botls or what to do if/when they do break off.

 

[Johnsram]

If they don't loosen easily (they are torqued to only 18 lb. ft.) heat the bolt with a torch, then remove. When reinstalling headers or manifolds, use ss bolts, tighten only 18 lb. ft., strictly following the tightening sequence.

 

[Redtruck-VA]

This sounds like it has been a long term problem. The manifold may nolonger have a good sealing surface. I would spray the bolts for a couple of days with penetrating oil. Pull inner fender liners. Drop the pipes and have at it. With the header removed there maybe enough of the bolt left to get a pair of vice grips on. Lot of penetrating oil and some heat if needed. If broke off flush sometimes a nut can be welded onto it. If that fails, then I would remove the head to properly remove the broken bolt. Good luok

 

[JoeRam14]

This sounds like it has been a long term problem. The manifold may nolonger have a good sealing surface. I would spray the bolts for a couple of days with penetrating oil. Pull inner fender liners. Drop the pipes and have at it. With the header removed there maybe enough of the bolt left to get a pair of vice grips on. Lot of penetrating oil and some heat if needed. If broke off flush sometimes a nut can be welded onto it. If that fails, then I would remove the head to properly remove the broken bolt. Good luok

Agree. Lots of spray penetrating oil for several days. When I did mine I soaked then twice a day for a week. Came out smooth like butter.

 

[Johnsram]

I never had much luck with penetrating oil with the bolt head and manifold flange in the way...unless they are already loosened.

 

[rwreuter]

If they become a real PIA, mig weld a nut to the broken off stud and then back it out.