So i'm replacing my exhaust manifold because the old one had a crack on one of the pipes causing it to leak....and me to not pass emissions test.

As I go to tighten the exhaust manifold bolts...Crack!! i broke one...and its the hardest one to get (of course, nothing in life is easy) the one nearest the AC and alternator.

Any ideas on how i can get it out and replace it?

what size Easy out should i get?

and other suggestions?


Thanks

 

As you said, you should try an easy-out, although I haven't had very good luck with them. I guess you'd use the largest size that's smaller than the bolt, right? Don't forget penetrating lube and a blowtorch, although I somehow doubt those will help much.

Another option is to drill out the bolt and use a time-sert http://www.timesert.com or a helicoil/permacoil. I snapped off an M6 bolt just the other day, and I drilled it out and repaired the threads with a permacoil. It was super-easy, although I had complete access to the spot where I was working. I think that time-serts are supposed to be better than heli/permacoils, although people apparently use heli/permacoils to repair head bolts pretty frequently. I assume an exhaust manifold bolt is under less tension than a head bolt, dunno.

I almost forgot: you can just drill it out and tap the hole for a larger bolt. Anyway, the point is that you have options.