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Ram 1500 5.7 broken exh man bolt replacement #2604560
01/10/19 07:02 PM
01/10/19 07:02 PM
Joined: Apr 2007
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Calgary, Alberta Canada
a12rag Offline OP
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a12rag  Offline OP
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Just curious for those with 2009 up Ram with 5.7 - have you gone through the broken bolt on exhaust manifold replacement ???

https://www.youtube.com/watch?v=vDlk7B-PRAA

Has anyone tries his technique of holding a nut against the head and weld the inside to the broken stud ?? Looks pretty good and better than trying to drill and tap . . .

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2604585
01/10/19 07:49 PM
01/10/19 07:49 PM
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Renton Washington
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Triple Threat Offline
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I had a 2010 5.7 truck that broke the bolts twice. First time it was fixed under warranty. Second time I just drove it for a year until I traded the truck in.

Sorry, not much help but a very common issue.


-Dustin
67 Dart, 9 second, 392" G3 Hemi
68 Barracuda 340 F/SA
Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2604586
01/10/19 07:54 PM
01/10/19 07:54 PM
Joined: Jan 2003
Posts: 32,882
Grand Prairie,Texas
stumpy Offline
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Every broken stud I had on my hemi came out with a pair of vise grips. They don't get stuck in the head they just break off from vibration. If you get one broken off even with the head try using a sharp pointed tool to unscrew it.

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2605482
01/12/19 04:46 PM
01/12/19 04:46 PM
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UPPER MICHIGAN, MARQUETTE COUN...
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NITROUSN Offline
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We do it all the time. We always weld a flat washer to the stud first. Then weld a nut to the flat washer. Using a flat washer it is easier to center over the stud and it also allows a better weld penetration to the stud. You can then use a larger nut and weld that to the washer. The smaller the nut the harder it is to get the penetration needed to the stud. Of course if the stud is sticking out it is a whole lot easier to weld to.

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2606084
01/13/19 08:04 PM
01/13/19 08:04 PM
Joined: Apr 2007
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Calgary, Alberta Canada
a12rag Offline OP
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Good idea on the washer !!

Has Mopar come out with any better studs/bolts to cure the problem ???

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2606131
01/13/19 09:31 PM
01/13/19 09:31 PM
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Round Lake Beach, Illinoisy
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My 2015 Ram did this in the first year, it only ticks when cold, and goes away quickly, so I just live with it... shruggy


The funny thing about science is that if you change one miniscule parameter you change the entire outcome to the way you want it.

JB Rhinehart, Realist

A-Body's RULE!
Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2606153
01/13/19 09:58 PM
01/13/19 09:58 PM
Joined: Sep 2007
Posts: 1,032
Fitchburg, WI
BIGHOOK Offline
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Originally Posted By a12rag
Good idea on the washer !!

Has Mopar come out with any better studs/bolts to cure the problem ???


I thought I read somewhere that the 6.4 Hemi exhaust manifold bolts are stainless steel/higher grade bolts and could be substituted for the 5.7 bolts. I believe Dodge only offers the OEM 5.7 cheapy bolts from the dealer. However, there may be aftermarket upgrade bolts.

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: BIGHOOK] #2606197
01/13/19 11:17 PM
01/13/19 11:17 PM
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ND
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dodgedon Offline
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I just bought studs for my 2012 and asked if there was an upgrade. He said the number was superceded but didnt know why....

I used to work in a reman shop and we welded nuts to broken bolts and studs all the time. In most cases we were using an impact wrench to back them out.


67 Charger 383 auto
75 Dodge CNT 800 CAT Diesel
2012 Ram Crew cab 5.7 4x4
Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2606215
01/13/19 11:55 PM
01/13/19 11:55 PM
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chicagoland,usa
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buildanother Offline
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By the way, mopars are not the only mfgs with these exhaust issues. Have seen plenty broken bolts since 1984 or so.

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: buildanother] #2606354
01/14/19 11:10 AM
01/14/19 11:10 AM
Joined: Jun 2006
Posts: 472
Central NY
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GarageDodge Offline
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Central NY
Ford 5.4&v10 are the worst,we do alot of them.They usually don't come out easy,some you end up drilling&taping.Have only had to drill a couple of 5.7,they usually come out by welding a nut on them.

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2608424
01/18/19 03:01 AM
01/18/19 03:01 AM
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ND
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dodgedon Offline
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I did mine today. Found 1 broken stud. Everything came apart with hand tools.

20190117_122947.jpg20190117_122859.jpg20190117_122837.jpg

67 Charger 383 auto
75 Dodge CNT 800 CAT Diesel
2012 Ram Crew cab 5.7 4x4
Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2608616
01/18/19 03:14 PM
01/18/19 03:14 PM
Joined: Apr 2007
Posts: 2,914
Calgary, Alberta Canada
a12rag Offline OP
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Awesome !!! . . . was the drivers side or pass side ??? Oops, looking closer, looks like pass side ??? You get the bolt package from Mopar ? Did you take the wheel well liners off and go in from there ?? . . .

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: a12rag] #2608711
01/18/19 06:40 PM
01/18/19 06:40 PM
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ND
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dodgedon Offline
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Yes, passenger side. Took the tire off and the plastic wheel well out.


67 Charger 383 auto
75 Dodge CNT 800 CAT Diesel
2012 Ram Crew cab 5.7 4x4
Re: Ram 1500 5.7 broken exh man bolt replacement [Re: GarageDodge] #2609309
01/20/19 01:45 PM
01/20/19 01:45 PM
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Mi,U.S.A.
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mike s Offline
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Later 5.7L all use SS bolt/studs at rear 2 bolts.Make sure the dealer sells you the bolt/studs with white painted end. Fronts are different. Fix? Drill out the small bolt line up hole in the exh manifolds (manifold can not bind then). Manifold grows and binds,breaks the bolts (not the bolts fault).


Leave the gun.......take the Cannoli's....Mike
Re: Ram 1500 5.7 broken exh man bolt replacement [Re: mike s] #2609651
01/20/19 11:54 PM
01/20/19 11:54 PM
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Southeast Pa.
SALEM1912 Offline
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As stated these stud seldom get "seized" in the head. Done alot of them and have good luck soaking them and tapping them out with a ice pick type chisel.

Re: Ram 1500 5.7 broken exh man bolt replacement [Re: mike s] #2609824
01/21/19 12:52 PM
01/21/19 12:52 PM
Joined: Apr 2007
Posts: 2,914
Calgary, Alberta Canada
a12rag Offline OP
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a12rag  Offline OP
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Originally Posted By mike s
Later 5.7L all use SS bolt/studs at rear 2 bolts.Make sure the dealer sells you the bolt/studs with white painted end. Fronts are different. Fix? Drill out the small bolt line up hole in the exh manifolds (manifold can not bind then). Manifold grows and binds,breaks the bolts (not the bolts fault).


I was wondering what the issue would be, I have a 06 Magnum with 5.7, and 133k miles on it, no issue with exhaust what so ever, must have changed the exhaust manifold design . . .







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