Well I worked on the truck some today. I got the timing chain changed and the gasket cleaned off the block and cover. I have the cover soaking in cleaner to get all the oil and grease off of it. I also took the exhaust manifolds off to install the long tubes but did brake one of the studs in the pass side its broke even with the head. Anyone have any advice on getting it out without removing the head? On the driver side all the bolts came out one stud came out but the other the nut came off leaving the stud in. What would be the best way to remove that?

 

I've seen tricks where you weld a nut on the face of the broken bolt shaft and then remove it. There's all kinds of vids on youtube about broken bolts and such. The hemis have a bad rep for this exact issue.

 

quickest and easiest way to clean the timing cover is to spray it with oven cleaner. let it sit for about 20 minutes and then wash it off. will come out super clean. this trick also works for head, intakes or anything that is covered in oil, grease or carbon.

as far as the broken bolt goes there is a couple ways to go after it but it really depends on your tools. welding a washer onto the bolt and then welding a nut to the washer works sometimes. if you don't have a welder you can just go straight for drilling the bolt out as large as you can without hitting thread and then using an extractor. if that don't work keep drilling till it is close enough to the right size and re-tap the hole

 

Planning on getting mine done in spring. Gotta put a motor in my jeep first though-meed wheels while it's torn down. I will be taking care of the plenum, replacing the timing chain-double roller-and cover, water pump, and oil pan gasket while I'm in there. And of course, whatever else I find while doing the work. Starting at the back on the top, ending up at the back on the bottom. In the meantime I battle varios vac leaks, no heat issues, vibrations, broken dash yadda yadda yadda....... Just replaced cap wires and rotor due to a misfire issue, and did the cheap O2 sensor trick to negate the cat inefficient light.

 

Place a washer over the flush broken stud. Weld through washer to stud. Weld bolt to washer. Let it go cold. Heat the manifold with oxy/acet until you get a nice glow, burp broken stud out with impact gun. Tap/clean hole, insert new stud. If you don't have access to a welder, find a muffler shop with an old phart like myself working there, usually 20 bucks will get it done. I have literally pulled thousands of broken studs out of manifolds. Got rather proficient at it over 15 years in the exhaust business...
Yes, I have a welder, oxy/acet torches, so I still do this stuff for myself or friends.

 

I got the broken bolt out of the head. I'm going to get the other stud out tomorrow which I'm hoping come out. I'm also hoping to get the timing cover and intake back on. When installing the gaskets in the timing cover should I use anything on the gaskets? Spray tack or rtv or anything? Same goes for the intake?

 

Thin layer of rtv around the coolant passages on the timing cover, and intake. Should be all you need.

 

 

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