Hello, I have a 2003 Dodge Ram 1500, 4.8L, V8, 4x4, SLT, extended cab, Gas, with 120k miles. I started to replace the ignition coils and spark plugs, and 4 of the 8 bolts were so rusted they broke off when I tried to remove the nuts. How can I replace the broken bolts? Can I just remove them from under neath the intake manifold, and replace with new ones? Are the bolts threaded into the block/intake manifold? I am hoping I do not have to remove the intake manifold to do this. Any help would be appreciated. Thanks!

 

You could try to drill a hole in them and use an easy out.

 

There is no attachment inside the manifold. It's just a threaded sleeve in the manifold, I think. An Easy-Out may be your only answer, short of a new plenum. Meanwhile, a little PB Blaster on the remaining bolts would be worthwhile.

 

Dang, I was hoping to just hammer that bolt out the other side, but guess the bolt extractor/easy out is one option. I ran the engine for about 1/2 hour to bring up the engine temp, get the bolts hot and sprayed industrial rust breaker occasionally over 2 days, but the nuts were rusted so bad it was welded to the bolt. Thanks for the heads up.

 

The coils snap on pretty tight. I wonder if they even need to be bolted down but not a good idea. Sounds like there rusted pretty good. Unless your professional grade have fun drilling and using an easy out and you have four to boot. Another possibility not the best though is drill a 3/16 hole into the stud and use a appropriate size stainless steel self tapping screw to hold the coil on.
If you do try the easy out what ever you do don't buy cheap easy outs. YOU WILL BE SORRY.