How do I...... Remove a Rusty and Rounded Exhaust Manifold Bolt??? - MG-Rover.org Forums
 
 
 
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Old 12-02-2008, 14:58   #1
davemcc43
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How do I...... Remove a Rusty and Rounded Exhaust Manifold Bolt???

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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Old 12-02-2008, 21:11   #2
GeordieEnglish
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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-B.../dp/B0000CCXVZ. then these are a godsend. Hope this helps.

Geordie
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Old 13-02-2008, 19:00   #3
martinhodge
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u can get a socket set that will cut nuts down to there next size not cheap though .

word of advise to others allways undo them after having the car running for ten mins or so to get them really hot . then do it will come off like butter
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Old 16-02-2008, 16:47   #4
davemcc43
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GeordieEnglish - Thanks for the tip. Would not using such a high concentrated heat damaged the head which is alloy based?

martinhodge - A valuable tip for the future!

DAVE
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Old 18-02-2008, 20:28   #5
GeordieEnglish
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The flat piece of the exhaust manifold where it joins the head will function as a heat shield when heating the bolt. Just come at the bolt from an angle 90 degrees if you can. This will save your head from heat and the manifold can cope with it.
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Old 21-02-2008, 23:33   #6
tuned820
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Try Getting A Socket The Next Size Down Whack It On With A Hammer Should Go On Tight And Make It Possible To Come Off Should Pull The Stud At The Same Time Cause There Double Ended Studs.
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Old 22-04-2008, 02:30   #7
khooper
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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.

__________
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Old 28-04-2008, 17:11   #8
jamie_anderson
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Quote:
Originally Posted by tuned820 View Post
Try Getting A Socket The Next Size Down Whack It On With A Hammer Should Go On Tight And Make It Possible To Come Off Should Pull The Stud At The Same Time Cause There Double Ended Studs.
i would heat it up till red hot with oxy-aceltaline torch then put the next size down socket on then let it cool it knacks the socket but should work.
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Old 28-04-2008, 18:25   #9
liamfleming
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u cud grind it off and drill it out and re tap it

or weld a new nut on it and remove it that way ..
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