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Old 02-06-2012, 06:17 PM   #1
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Broken bolts, what to do?

While working on my 97 TJ 2.5 wrangler today one of the bolts that connects the front exhaust pipe to the manifold broke. What is the best way to get it out? I am worried about taking off the manifold because i dont want to break anymore bolts.

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Old 02-06-2012, 06:21 PM   #2
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drill it out..

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Old 02-06-2012, 06:28 PM   #3
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How? Sorry i have no experience with broken bolts, do i need to buy a kit to tap it out or is there a certain bit i can use?
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Old 02-06-2012, 06:55 PM   #4
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Drilling it is going to be about the only way.
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Old 02-06-2012, 07:00 PM   #5
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They sell kits called "easy outs". Dont let the name fool you though, they should be called "pain in the ass outs"... but, they usually work. They come with a drill bit that you use to drill down the center of the broken bolt. There is then another part that threads into the hole you just drilled (reverse thread), which allows you to turn the bolt out (hopefully).

good luck
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Old 02-06-2012, 07:05 PM   #6
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Are the holes leading from the manifold to the exhaust pipe threaded?
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Old 02-06-2012, 07:12 PM   #7
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i did the same thing sat ! broke the inside one, Get a small grinder and grind the stud flush with the manifold, then go to the hardware store and pick up some long drill bits , I ended up using a 5/16 nut and bolt, the nut will go up top , because the bolt wont drop down because theres no room .
About a 15 minute job
and get some cutting oil
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Old 02-06-2012, 09:14 PM   #8
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Do not break the easy out in it. You will never drill that out. It will have to be torched out.
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Old 02-06-2012, 11:17 PM   #9
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Easy outs are a good option. Before drilling the center hole, hit the area with a center punch to give the drill tip a foothold and prevent it from walking.

Another option is to weld on another bolt to the existing one.

And yet another option is to drill out the current bolt and install a helicoil (not my favorite option but it can be done)
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Old 02-06-2012, 11:34 PM   #10
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If you've NEVER done it, my suggestion would be to FIND someone who has.
Have them SHOW YOU how. Should you attempt it, and mess it up, it WILL be
a costly mistake to correct.
I'll just add this ~~~ EVEN a Pro can screw it up, BUT then HE has to make it
right, not you.
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Old 02-07-2012, 12:07 AM   #11
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get a set of reverse drill bits kinda like easy outs but easier to use if u ask me. im a mechanic and find myself using them often


but then again i have never used them on an exhaust manifold im sure that bolt is nice and rusty
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Old 02-07-2012, 01:06 AM   #12
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Quote:
Originally Posted by netlohcs View Post
They sell kits called "easy outs". Dont let the name fool you though, they should be called "pain in the ass outs"... but, they usually work. They come with a drill bit that you use to drill down the center of the broken bolt. There is then another part that threads into the hole you just drilled (reverse thread), which allows you to turn the bolt out (hopefully).

good luck
+infinity
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Old 02-07-2012, 10:15 PM   #13
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Quote:
Originally Posted by CoyoteOn2 View Post
If you've NEVER done it, my suggestion would be to FIND someone who has.
Have them SHOW YOU how. Should you attempt it, and mess it up, it WILL be
a costly mistake to correct.
I'll just add this ~~~ EVEN a Pro can screw it up, BUT then HE has to make it
right, not you.


Listen to this guy you could be creating yourself a mess that will be way expensive to get out of.
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Old 02-07-2012, 10:38 PM   #14
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I agree. Then the Mechanic or Shop is responsible. As others have said, not an easy problem to deal with.

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