hey guys, my cousin and i are in the process of installing my new performance header. we ran into a bit of a problem (below) though. when we removed heat shield, we found that two bolt heads snapped off, causing the manifold to leak on the outer parts and the manifold was cracked. good thing we found it this early! once the new one is on, should notice a great improvement in sound and performance.

http://i180.photobucket.com/albums/x...d001resize.jpg

well, we tapped a bolt extractor onto the first bolt, came out fine! however, the second started, but then snapped off even more, lying flush with the head...

http://i180.photobucket.com/albums/x...d004resize.jpg

we are going to attempt to tap it then use an ez-out. some have suggested welding a new bolt on to extract it, but that is much too risky becuase of the aluminium, not to mention no space whatsoever as far as surface area is concerned. has anyone had any experience with this problem? if the thread becomes somewhat damaged, we may have to tap the hole larger, which isnt much of a problem.

i would just like input on any possible solution to avoiding removal of the head itself, that would be last resort. any help is greatly appreciated. i will let you all know how the tapping attempt goes tommorow or sometime this weekend.

 

The easy out should work for you and that is the typical spot of an exhaust manifold crack.

 

yeah i knew that the crack was typical, i was more concerned about the fact that two heads snapped off causing those leaks[:'(]

using the easy out tonight or this weekend, ill keep you posted on how it goes. header install should be smooth sailing from there.

 

What header are you installing and where did you buy it? I've seen a relatively inexpensive one on eBay for the SOHC and was wondering if it was worth while....

 

Just read your signature.... nevermind about the one you have...

Not to hijack the thread, but does anyone know if the inexpensive manifold off eBay is worth the time?

http://cgi.ebay.com/ebaymotors/95-99...spagenameZWDVW

Looks cute

 

doesnt look half bad. i wouldnt know about the stuff on ebay, i avoid aftermarket stuff like that from those types of sellers.

oh and update! got the broken bolt out, took a right angle adapter for a drill and it performed nicely.
alternator is back in, extenstion and flange is intalled. probably gonna wait until tommorow to finish installing the header. peace!

oh and performancecenter.com is having a sale on Pacesetter headers for the neon at least (painted and Armor coat alike. i got my Armor coat one for $231 shipped!) Sale might still be on, so check it out Mich.

-Zach

 

when i did my headder i had 4 broken bolts all on the bottom so it made it really esay to get it out but just used vice grips to remove the broken studs was pretty easy