Please post these in the same thread you originally started for this issue, do not create separate threads. Will merge them together for you.

 

Doesn't sound too far fetched. Anything that has to do with exhaust removal can be labor intensive, especially where bolts are involved. They rust, weaken, snap, strip, etc. These truck exhausts were installed using bolts that were not up to par. A lot of us have had broken manifold bolts. The reason is subpar bolts and the rubber motor mounts. Dodge used rubber motor mounts instead of the much stiffer polyproylene. The rubber not only allows more side to side torque shake but, if you have someone put it in gear and give it gas, you can easily see the engine shift front to back. Too much stress for those bolts. The only cure would be to drill out all the holes and re-tap for a larger diameter bolt. Removal of the snapped bolts can range from piece o cake to nightmare. First attempt would be cutting a slot into the bolt and trying to remove with a big screw driver. If that doesn't work, it's drill and tap time. If lady luck is smiling at you, there will be enough stud sticking out to get a vise grip on but, I wouldn't hold my breath waiting for that scenario. You could check the service manuel to see the manifold removal process and compare to what your mechanic has outlined.