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Pics of broken exhaust manifold bolts


Old 09-02-2012, 09:04 AM
TrueDogman is offline
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Default Pics of broken exhaust manifold bolts

Just a few pictures for all the diy guys and gals.

03 5.7 with 60k

-disconnected battery
-removed wheel well liners
-used torch and basic hand tools

I was going to change exhaust bolts as a preventative, but low and behold, once I got in there, found the rear bolt on the passenger side had already broken. I had no exhaust leaks noticeable.

I did replace heat shields and used oem bolts on both manifolds.

I cut or broke the heads holding the heat shield on. Some of these small 10mm nuts were rusted so bad there was no way to get any size socket on them properly....thus the torch.

Most exhaust manifold bolts came out on their own with a socket and ratchet. The ones that didnt feel right when attempting to loosen.....I cut the bolt heads off, leaving the stud. The manifolds then slipped off the cut bolts. Once the manifolds were off, these remaining bolts I had cut screwed out with my fingers.

The broken bolt was a bit of a pain. After carefully drilling dead centre, and a couple of easy outs with some PB blaster I managed to extract the broken bolt without any thread damage to the head.

good luck everyone tackling this job!

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Old 09-02-2012, 09:40 AM
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HammerZ71 is offline
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Sadly, this is another issue that has gone on for over a decade now that Chrysler/Daimler/Cerberus/Fiat has done nothing to remedy. Broken manifold bolts are common on every engine, in every vehicle they produce(d)...
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Old 09-02-2012, 01:38 PM
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Location: Oklahoma
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I had the same problem on my 03. But it didnt start until about 147,000 miles. I noticed a loud ticking noise until the truck would warm up.
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Old 09-02-2012, 05:57 PM
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Posts: 86

Had 2 on the passenger side when I replaced mine. And My brother-n-laws 2010 Hemi has had the same problem. Passsenger side rear bolts.
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Old 09-02-2012, 06:24 PM
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Location: New Jersey
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Very nice, thanks for the pics!
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Old 09-02-2012, 06:48 PM
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snidehockey is offline
Join Date: Dec 2008
Location: Orlando, Fl.
Posts: 77

Ironically I signed into the forum because I just found a broken rear passenger bolt on the manifold today when I was doing my passenger ball joints.

I had to chuckle when the first topic on the list was this.

I won't threadjack though...I'll start my own.
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Old 09-05-2012, 01:43 AM
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I had two of my own when I put my LT headers on. Good job on getting yours out and clear
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Old 10-05-2012, 08:27 PM
swanner is offline
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How did u get a drill in there? Did u pull the motor up? I have to do 4 bolts on my 2002. 4.7?
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Old 10-06-2012, 12:40 AM
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Excellent pics!
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Old 10-06-2012, 11:00 AM
TrueDogman is offline
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Sorry, cant speak for the 4.7. Once the wheel well liners were removed, I was impressed with the access I had to the manifolds and had lots of room. Didnt have to raise motor.
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