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More broken manifold bolts

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Old Mar 21, 2018 | 09:53 AM
  #1  
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mopar4u
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Default More broken manifold bolts

i found em on my 2005 1500 5.7. Is it safe to drive like this or is there risk damaging the engine?

im trying to determine if i want to tackle this myself or not. Looks like welding a nut to the subflush broken bolt is the way to go but im worried about damaging the head.

what hardware and gasket is recommended to prevent this from happening again?
 
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Old Mar 21, 2018 | 11:38 AM
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Other than annoying ticking, hemi-tick, there is no damage being done. Unless of course there are many bolts broken. Also realize that the ticking is exhaust gas leaks. Meaning fumes under hood and potential being drawn into the cab. Just to not sit idle in one place for a long time, you may get a headache.

It actually is not a difficult job. A bit time consuming yes, but not hard. Put the front of the truck up on stands, make sturdy, make safe. Remove the front wheel(s). Remove the fender liner(s). Giving full clear access to the exhaust manifold(s). The level of challenge of removing the broken bolts really depends on where they broke off. Sometimes the broken stem can be removed with a few turns of the finger tips. Sometimes pliers. Sometimes need to weld a nut on to get the torque to turn it. Sometimes a bit of drilling and an easy-out.

As for hardware. Many go with OEM Mopar. Depending on your approach of replacing only the broken bolt or replacing them all, that can get incredibly expensive. When I did mine, I replaced all of the bolts all at the same time. I used FelPro gaskets and the Dorman bolt kit for a fraction of the cost.

A couple of tips that may be helpful.
- The bolts fail from fatigue, time and heat cycles. If you are going to change one, change them ALL on BOTH sides at the same time. Else you will be repeating the job again soon and then complaining that it keeps breaking bolts. When really it is just breaking the ones you didn't change.
- Do not try to reuse the gaskets. Install new.
- Clean the threads of the head. Take an old bolt in good condition. Use a file or grinder to cut threads along one side of the bolt, lengthwise. Basically turning it into a tap. Oil the head hole. Run that cutter bolt into each hole 2 - 3- 4- times. Rinsing out the hole with spray oil each time.
- Good times to look at exhaust valves. Roll the engine over by hand, turning the crank with a wrench. Inspect each cylinder valve as it opens. If you see valve cupping, put a valve job on your future todo-soon list.
- Clean the manifold with a wire brush. Inspect the manifold for cracks. Clean and polish the exhaust port gasket surfaces.
- Use high temperature anti-seize on the new bolts when installing. If you ever have to do the job again, much much later from now, you will be thankful you did.
- When tightening the bolts, change the sequence from what you'll find. Tighten from back to front rather than middle outwards. Reason being you want expansion to go forward, not rearward to snap the bolts again. Starting at the back, snug down the bolts (not tight yet) working way forward. Then go back with torque wrench, start at the rear and work forward. Go over with torque wrench 2 times minimum.
- Replace the heat shields. Some say not required. I say they are. There is ALOT of heat emanating and radiating off of the manifold. The shield protects nearby wiring, hoses, plastics from radiant and thermal heat damage. The shields ARE required.

Hope that helps!
 
Attached Thumbnails More broken manifold bolts-img_5914.jpg   More broken manifold bolts-img_5916.jpg   More broken manifold bolts-img_5917.jpg   More broken manifold bolts-img_5919.jpg   More broken manifold bolts-img_5922.jpg  

More broken manifold bolts-img_5923.jpg   More broken manifold bolts-img_5924.jpg  

Last edited by FaceDeAce; Mar 21, 2018 at 11:42 AM.
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Old Mar 22, 2018 | 01:15 PM
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thanks for the info

the dealership i bought it from gave me a 3 month 3000 mile drivetrain warranty. i called them up and they said they would cover it. my cost will be $100 deductible. thats the path im gonna take
 
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