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Removing snapped exhaust manifold bolts #2707863
10/17/19 08:43 PM
10/17/19 08:43 PM
Joined: Jun 2004
Posts: 730
NW PA
V10nacuda Offline OP
super stock
V10nacuda  Offline OP
super stock

Joined: Jun 2004
Posts: 730
NW PA
So I finally got my butt in gear and finished yanking the 5.7 out of the donor truck for my Ramcharger swap. I was just going to drop the motor and 545rfe as one, figure how much floor pan work i need to do. (I havent found anyone with the 545rfe swap) Get it running then yank it out and clean it up. Well shiny object syndrome got me and I decided to yank the valve covers to get them blasted while I did everything else.After a few of the valve cover bolts snapped off I decided to pull the exhaust manifolds too and broke 2 on top of the other 2 that were snapped off nearly flush.

So anyone have a full proof procedure for getting them out?

I have dealt witb cast iron heads and snapped bolts....Any alum heads I have had were new and were doused in never seize and never had issues.

Thanks in advance V10

Re: Removing snapped exhaust manifold bolts [Re: V10nacuda] #2707979
10/18/19 09:29 AM
10/18/19 09:29 AM
Joined: Jan 2003
Posts: 844
Odessa, Fl
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blowndart Offline
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blowndart  Offline
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Posts: 844
Odessa, Fl
If you have a welder, you can weld a nut to the broken stud (even if it broken flush with the head) and then back it out. I've done it and it worked great.

Re: Removing snapped exhaust manifold bolts [Re: blowndart] #2708160
10/18/19 04:23 PM
10/18/19 04:23 PM
Joined: Feb 2005
Posts: 15,042
PA.
pittsburghracer Online work
"Little"John
pittsburghracer  Online Work
"Little"John

Joined: Feb 2005
Posts: 15,042
PA.
Originally Posted by blowndart
If you have a welder, you can weld a nut to the broken stud (even if it broken flush with the head) and then back it out. I've done it and it worked great.




We dealt with Broken bolts and studs in the mill and learned that if we took a smaller flat washer and plug welded it to the broken stud it was then easier to weld a nut to the flatwasher and get a better cleaner weld.


1970 Duster
Edelbrock headed 408
6.143@110.85 mph
9.73@135.05 mph shifting at 6700 RPM
422 Indy headed small block
5.982@112.56 mph
9.42@138.27

Livin and lovin life one day at a time




Re: Removing snapped exhaust manifold bolts [Re: pittsburghracer] #2708494
10/20/19 10:04 AM
10/20/19 10:04 AM
Joined: Sep 2014
Posts: 481
Central Pa
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moparjim79 Offline
mopar
moparjim79  Offline
mopar
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Joined: Sep 2014
Posts: 481
Central Pa
Originally Posted by pittsburghracer
Originally Posted by blowndart
If you have a welder, you can weld a nut to the broken stud (even if it broken flush with the head) and then back it out. I've done it and it worked great.




We dealt with Broken bolts and studs in the mill and learned that if we took a smaller flat washer and plug welded it to the broken stud it was then easier to weld a nut to the flatwasher and get a better cleaner weld.


Wow, never thought of this, great tip!

Re: Removing snapped exhaust manifold bolts [Re: moparjim79] #2708720
10/20/19 10:44 PM
10/20/19 10:44 PM
Joined: Jun 2004
Posts: 730
NW PA
V10nacuda Offline OP
super stock
V10nacuda  Offline OP
super stock

Joined: Jun 2004
Posts: 730
NW PA
Well got the all out by welding the nut to it! The washer idea is filed in my memory bank for future issues!

Thanks!
V10

Re: Removing snapped exhaust manifold bolts [Re: V10nacuda] #2716174
11/15/19 05:30 PM
11/15/19 05:30 PM
Joined: Aug 2007
Posts: 2,264
Kentucky
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dfsmopars Offline
top fuel
dfsmopars  Offline
top fuel
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Joined: Aug 2007
Posts: 2,264
Kentucky
Do the manifold gaskets have to be replaced or are they reusable?


‘72 Charger, 5.9 Magnum, Tremec 5 spd., Pro-Touring
‘14 Big Horn, Quad Cab, 4x4, 1500
Re: Removing snapped exhaust manifold bolts [Re: dfsmopars] #2717140
11/18/19 11:34 AM
11/18/19 11:34 AM
Joined: Jun 2004
Posts: 730
NW PA
V10nacuda Offline OP
super stock
V10nacuda  Offline OP
super stock

Joined: Jun 2004
Posts: 730
NW PA
I believe exhaust gaskets are not reusable.

Re: Removing snapped exhaust manifold bolts [Re: V10nacuda] #2717199
11/18/19 01:49 PM
11/18/19 01:49 PM
Joined: Nov 2003
Posts: 5,119
Fort Worth, Texas
3hundred Offline
master
3hundred  Offline
master

Joined: Nov 2003
Posts: 5,119
Fort Worth, Texas
Originally Posted by V10nacuda
I was just going to drop the motor and 545rfe as one, figure how much floor pan work i need to do. (I havent found anyone with the 545rfe swap)


Mine has the 545rfe but it's two wheel drive so I don't know how much help that would be to you. I did put an A-500 into an older 2wd Ramcharger, TONS of room. I simply don't know about the 4x4 and transfer case clearance.

Robert


'68 Fury Convertible
'69 300 Convertible
'93 Ramcharger 5.7 Hemi
'93 Ramcharger 318 sold
'01 3500 4x4 Cummins 6 speed sold
'13 300 S sold
'15 Durango 5.7 Hemi
'16 300 S Hemi

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