Exhaust manifold bolts

[Nucky42085]

My 2015 1500 Laramie 5.7 hemi has at least 2 broken exhaust manifold bolts on the drivers side. First 2 bolts at cylinder 1.
I'm thinking about doing this job myself.
For anyone that has done this or knows about it...with at least 2 busted bolts, what would the likelihood be that I break another 1 or 2 bolts trying to remove them?
I'm just wondering, at 111,000 miles and 2 broken bolts, are the rest going to be super brittle and snap the head off?
I don't want to be drilling out half the bolts and honestly, I'd expect the drill bits I use will dull out after a couple anyway.

I just replaced my exhaust manifold back in Feb. Had 7 broken bolts and 6 were snapped off flush. I didnt want to drill out the bolts and damage the manifold. So I welded on a nut to the broken bolts and got them out that way.

 

[EdGs]

I just replaced my exhaust manifold back in Feb. Had 7 broken bolts and 6 were snapped off flush. I didnt want to drill out the bolts and damage the manifold. So I welded on a nut to the broken bolts and got them out that way.

Damn, you must've had the front and back bolts broken on both sides.

 

[dacheedah]

My was done at about 25,000 miles and I did both sides at 90,000 ish. Not hard, I did weld a washer and nut on drivers side to front and rear bolts. The videos make it look like it works first time and I had one that worked great, second took about 5 trys before it the weld held, it did work. Once you pull the manifold the bolts are not very tight. I did chase all the threads before reassembly, I have a mill and used the table to check level on the manifolds, warped badly. I asked a machinist friend of mine and he said they use a big belt sander vs a flycutter on the mill. I did end up using a sander taking very small and checked it with steel blue compound and the mill table for rocking and it took several passes to level it. Not hard or expensive that way and the feeling is the manifold is seasoned and would hold.

 

[Dam Ram Jam]

after putting everything back together I took it for a spin around the neighborhood. notice a burning smell that comes and goes stronger then fades. is that just oils burning off the new manifold? I did not put the het shields back on. drivers side did not have the 2 front bolts holes anymore and there wasn't' one on the passenger. was planning on getting 2 new ones and putting them on, but for now, I have none on the truck. from what I've read, with this bd diesel kit the heat shields are 100% necessary.

 

[Dam Ram Jam]

Manifolds look like a banana, normal IMO.

Belt sand it flat, new hardware and gaskets, it'll be good-to-go. You don't need fancy grade 8 hardware, either. Once you sand those manifolds flat, they shouldn't warp again.

Did you get the broken studs out? Looks like there's a piece in there on your #1 cylinder, top left in your last pic?

Odd that some of your bolts were 3/8 heads, I'd be checking threads just to be safe. I don't remember the thread pitch of those bolts.

ya, the 2 bolts on cylinder 1 were broken off. top was flush and bottom was recessed a bit. got them off though without too much trouble

 

[Oliver Closehauf]

Here is a video about the welding method. They are selling a cool tool, but it's more about the job if you went that way.

EZ Stud Out Ford 5.4 exhaust studs removal

Another amazing video by EZ Stud Out showing how easy it is to remove broken exhaust manifold studs... even on a Ford... even when the stud is broken deep in...

www.youtube.com

 

[Ram Night]

Don't be that guy, you know very well he's referring to the heads.

This is true but the heads are aluminum.

 

[Ram Night]

My 2015 1500 Laramie 5.7 hemi has at least 2 broken exhaust manifold bolts on the drivers side. First 2 bolts at cylinder 1.
I'm thinking about doing this job myself.
For anyone that has done this or knows about it...with at least 2 busted bolts, what would the likelihood be that I break another 1 or 2 bolts trying to remove them?
I'm just wondering, at 111,000 miles and 2 broken bolts, are the rest going to be super brittle and snap the head off?
I don't want to be drilling out half the bolts and honestly, I'd expect the drill bits I use will dull out after a couple anyway.

I would consider an exhaust manifold kit from DB Diesel. These are built to last and come with bolts and gaskets.
This is my plan when I have this issue with my 17

 

[Wild one]

This is true but the heads are aluminum.

What in hell are you talking about?? And just why are you quoting me,maybe go back and reread all the posts.

 

[04fxdwgi]

That kit is pretty slick, especially with the flex MIG head. Probably going to get one for the Hemi