Hey everyone... I have a 2000 1500 with a 5.9. Had an exhaust leak that turned out to be the manifold on the pass side. Bolts were so rotted i tourched the heads off. Even after the heads were tourched the manifold still wouldn't budge. Big pry bar and a hammer it finally came off....problem is the front and rear bolts all snapped flush with the head and the two center stuck out a bit but just won't budge. I drilled and tried to easy out the front two but wasnt happening even with heat.
So my question is can I drill the head out and re tap the next size without f ing anything up? Also what size thread is in the head now?
Thanks
Eric

 

i don't think so. you'll end up f'ed up.

drill out the center of of the broken bolts with progressively larger drill bits and ease-outs and heat. at some point the broken bolts will give it up and come out. try to save the original threads.

 

Size thread?

 

ez-outs su*k, it will break off inside the bolt then you'll be really pis*ed off..use lots of pb blaster, repeat and take your time and the longer you wait and more often you do the better..then center punch the bolts..and this step is KEY! you don't want the bit to walk or go off center..like dhvaughan said start with a small bit and increase in size..remove as much of the bolt as possible..near the end put the drill in reverse to assist in removal...if you do use an ez-out wait till there's very little bolt left..good luck and post up the results

 

It's also possible to weld a washer and nut to the bolt in an attempt to extract it.

 

there's write ups and vids all over the place on the welding trick..if you have a welder do it that way for sure!

 

blaster and a left handed drill bit worked for me, the drill bit cuts into the bolt in reverse and about half way in the bolt started to come out like magic. just go slow and cautiosly

 

Not super forum savvy...where can I find the washer nut welding trick?
Also where is the best place to get the replacement studs? Dealer?
And...are the studs or bolts?

From what I could see was left of mine looks like outside 4 were bolts and middle two were studs.

 

yup outsides are bolts, mids are studs..Rock auto has them cheap, just bought them myself..youtube has vids on bolt extraction..this is the weld method

 

What size bit did you use? I'm gonna grab one tomorrow and give it a shot.