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How do I...... Remove a Rusty and Rounded Exhaust Manifold Bolt???

23K views 8 replies 7 participants last post by  liamfleming 
#1 ·
I'm trying to take the exhaust manifold off my VVC k-series as I break my old Rover Vi...

Fortuantely all the studs/nuts came holding the exhaust manifold to the block came off apart from, rather unfortunately, the middle one. This had completely burnt away and despite my best efforts the nut rounded off straight away....

I've tried a nut splitter but the nut and stud appear to have fused. And because of the exhaust pipes and the 'overhang' of the head from above I can't mole grips/plumbers pipe gripper/etc in there to grip the remains of the nut....

The only option that I can think off is the cut through the four branches of the manifold to allow me to remove the head, and then with the head on a bench, cut the branches off at the base, grind some flats into the offending nut and use an adjustable wrench to get it off....

But I'm looking for better ideas before I go to all this hassle!
I've done a search but haven't found anything,....

Thanks in advance...

DAVE
 

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#2 ·
Nut removal

Dave. I've had my fair share of rusted/rounded bolts and the best method i've found is heat. If you heat the bolt and then quench it with a drop of water 9 times out of 10 it will pop leaving it free to remove. I've used my blowtorch for this but with mapp gas instead of propane/butane mix (it burns hotter). Once a bolt rounded completely and nothing would get it off. In this case i had to fit a bigger bolt over the original and weld them together. It was then just a case of using a spanner on the new bolt. And if all else fails http://www.amazon.com/IRWIN-394001-Bolt-Grip-Remover/dp/B0000CCXVZ. then these are a godsend. Hope this helps.

Geordie
 
#7 ·
here is my suggestion :

Spray everything w/ a good penatrating oil the night before if possible. Use penatrating oil as you go anyway. Take a ball peen hammer and "tap" the head of the bolt solidly 9-10 times. Use 6 point sockets only on stuck bolts so you don't round the heads off. Put the socket on and tap the socket a couple of times. Put socket wrench on and while applying pressure, tap the wrench. DON'T do this on wrenches w/ a quick release mechanism. I wouldn't want to have one come apart in my face, Craftsman warranty or not. As or if it starts to turn loose keep giving it a few taps.
If this fails, repray and let sit a 1/2 hour or so and try again.
Don't know why "tapping" works, but it's along the lines of how an impact wrench works anyway. Hope I made this clear.

__________
The Pitstop
 
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