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Open Roads Forum  >  General RVing Issues

 > Broken/ leaking exhaust manifold bolts

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teddy360

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Posted: 05/13/19 07:08pm Link  |  Quote  |  Print  |  Notify Moderator

I have recently been experiencing exhaust leaks from my exhaust manifold, and it looks like I have a couple broken bolts on the manifold itself, which is where I think the leak is coming from. I have an 8.1L engine in my home, but what I am wondering is if anyone has any good/ affordable solution to the issue? I'm not the most motor savvy, so I have reached out to other people on other cites for input too.. I've seen everything from welding them out, to replacing the whole works at a shop, to trying K.A.P bolt repair kits. Any suggestions or recommendations?

Gonzo42

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Posted: 05/13/19 07:19pm Link  |  Quote  |  Print  |  Notify Moderator

The easiet solution is probably using an Eazy-Out. First you drill a pilot hole in the broken bolt then put the Eazy-Out which is threaded left-handed, tap lightly with a hammer, then turn it with a wrench to remove the broken bolt.

Get yourself replacement hardware from ARP, which has the best product for strength.


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teddy360

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Posted: 05/13/19 07:25pm Link  |  Quote  |  Print  |  Notify Moderator

That sounds like a good option too. I just don't want the bolts to continue to break since we put on a lot of miles every year. I thought the concept of the KAP bolt repair kit was interesting as well because it is like a clamp/ bracket that holds the manifold together, rather than an extraction and replace method. I haven't looked into it a ton yet, but that and your suggestion are probably my best bets for handling it myself. Thanks!

azdryheat

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Posted: 05/13/19 07:26pm Link  |  Quote  |  Print  |  Notify Moderator

It's somewhat easy to do but get a mechanic if you don't know what you're doing.


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fj12ryder

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Posted: 05/13/19 07:41pm Link  |  Quote  |  Print  |  Notify Moderator

That KAP bolt repair kit looks like the way to go. Trying to get into there and drill out the bolts to use an EZ-Out looks like a real nightmare. And I've seen quite a few broken EZ-Outs over the years, and they create a real mess.

Broken exhaust manifold bolts can be extremely stubborn to remove, and risk of breaking an EZ-Out is high. Not worth the hassle to me.


Howard and Peggy

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Posted: 05/13/19 08:36pm Link  |  Quote  |  Print  |  Notify Moderator

The OP suspects multiple broken bolts and would need a KAP kit for each bolt. Does it exist?

Is the exhaust gasket still intact? I'm doubtful since red hot gasses could destroy it given the broken bolts. The exhaust manifold might be warped or need to be replaced. Sometimes there are updated parts to correct problems so this should be checked.

Hopefully the KAP solution will solve the problem.


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Posted: 05/13/19 09:38pm Link  |  Quote  |  Print  |  Notify Moderator

They do sell jigs that keep a drill straight for that application, but sorry I can't remember the name. Once you get them out, go with Banks headers if you can afford it, or Thorley headers are also good and not as expensive. If the manifold is warped greater than .01 inch no gasket will seal it. If your going to keep the rig, then headers are a good way to go.


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ZINGERLITE

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Posted: 05/14/19 06:19am Link  |  Quote  |  Print  |  Notify Moderator

I just used a couple clamps on my half ton with a 5.3. Can't speak for how they'll hold up over time but my exhaust leak is fixed.

It seems like a halfass fix but it works and i don't need to take the head off.

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Posted: 05/14/19 06:36am Link  |  Quote  |  Print  |  Notify Moderator

X3 here on the easy out. If you go there once, that will be the first time and last on what to do next after the easy out snaps [emoticon]

schlep1967

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Posted: 05/14/19 06:49am Link  |  Quote  |  Print  |  Notify Moderator

Unless you have a good deal of experience, this is a job for a professional. An easy out may work but it will most likely take a lot of heat on that area to have any chance. Those bolt heads broke off for a reason. The bolts are rusted into the holes and you are very likely to break off the easy out. Once that happens and you now have a hardened chunk of steel in the middle of the soft bolt you need to get drilled out, the professional is going to cost even more.


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