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Old 12-10-2017, 08:28 PM
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Exhaust manifold Flange bolts

Need to replace my Exhaust manifold fold flange bolts on my 4.0L YJ engine are the 2 bolts pressed in or welded in. They are rusted bad and treads are missing

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Old 12-10-2017, 08:44 PM   #2
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They are pressed in give them a whack with a hammer they will pop out. Then replace them with regular bolts from the hardware store, i think i used stainless because when i have to take stuff apart i hate fighting rust.

That manifold looks like the original, 99% chance it's cracked and needs replaced though.

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Old 12-10-2017, 10:45 PM   #3
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It looks like you've soaked the studs as best you can. Do you have an oxy/acetylene torch to heat them with? If you heat the ear of the manifold and the bolt to dull cherry red and tap the bolt up with a hammer, it should pop right out.
If you don't have a torch, soaking and pounding is all you can do.

I expect the part of the bolt that is inside the manifold flange is knurled (well not actually knurled, but has teeth that bite into the wall of the manifold hole to keep the bolt from turning while the mechanic tightens the nuts on the exhaust pipe flange from underneath).

Per agalloch07s warning, check the manifold over carefully for cracks. A new one is under $150.00.

When you reassemble it, use Antiseize.

Good Luck, L.M.
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Old 12-11-2017, 12:03 AM   #4
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The ones I've seen aren't even pressed in but rather just dropped in...

Either way you shouldn't have to heat them just whack em with a hammer and they should pop right out
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Old 12-11-2017, 10:49 AM   #5
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It should just drop in the hole, but that one looks like its rusted to the manifold. I would put a wrench on and whack the wrench with a hammer to loosen it off and pull it out. If the manifold is off, just cut off the bottom threaded portion and drill the rest of it out.
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Old 12-11-2017, 12:02 PM   #6
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No you don't want to cut and drill anything... that turns a five second job into a three-hour job...

It's Hammer Time
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Old 12-11-2017, 12:17 PM   #7
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They are pressed in just like wheel studs i have replaced them on jeeps and dodge trucks. Even when they look so rusted you will never get them out all it takes is a solid hammer whack and they pop out. Factory used them so they were easier to assemble on the assembly line. Using a regular bolt will require a wrench on one side and a ratchet on the other and makes it a bigger pain in the ass. Especially when they rust and you have to juggle a wrench on the back side and a ratchet on the other and its so rusted it dont want to break loose. That's why i used stainless bolts so i don't have to fight with it if i ever have to pull the motor or exhaust to do engine/tranny work. You could probably get new press in studs from the dealer fairly cheap they used them on about everything.
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Old 12-11-2017, 01:26 PM
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Thanks guys I got them off I heated the flange then used a rag with ice water to cool just the bolt then hit it with a hammer the best I could and they popped out
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Old 12-12-2017, 10:14 AM   #9
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Quote:
Originally Posted by agalloch07 View Post
They are pressed in just like wheel studs .
I have never actually seen an original manifold bolt on the couple of old Jeeps I've worked on. Thanks good to know. Those bolts actually look good compared to what I am finding, half of the diameter is eaten away or the head of the bolt is round by rust on every bolt I touch on this old beast I'm working on.

And like posted I replace every bolt I take off this thing with new hardware. At this point I almost have a 2017 1993 Jeep...

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