Ram 1500 5.7 broken exh man bolt replacement

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 . . .

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.

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.

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.

Good idea on the washer !!

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

My 2015 Ram did this in the first year, it only ticks when cold, and goes away quickly, so I just live with it...

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.

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 He said the number was superceded but didnt know why....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.

By the way, mopars are not the only mfgs with these exhaust issues. Have seen plenty broken bolts since 1984 or so.

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.

I did mine today. Found 1 broken stud. Everything came apart with hand tools.

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 ?? . . .

Yes, passenger side. Took the tire off and the plastic wheel well out.

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).

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.

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 . . .