Removing snapped exhaust manifold bolts

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

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!

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

Do the manifold gaskets have to be replaced or are they reusable?

I believe exhaust gaskets are not reusable.

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