Remove a Broken Exhaust Manifold Bolt - EASY in 15 Minutes! No Disassembly!

This is a tutorial on how to remove a broken off exhaust bolt in a cylinder head without taking it off the engine! You do need to take the exhaust manifold off though. The video applies to any engine regardless of cylinder count.
If you have a car question ask it completely free at www.2carpros.c...
*Disclaimer: Please use all safety precautions

[@dunaweezel]

in a perfect world maybe

[@kevinagnew6878]

Some time you have a lot of rust and a few inches of room to do it

[@amauryburkes645]

@@kevinagnew6878dead mass less then half a inch of room to to get to the second bolt shii built so retarted

[@samd.4713]

@@kevinagnew6878exactly my situation SMH

[@PeggySue494]

Legit just got a bolt out with his method😆🫡

[@OMGWTFFYA]

Mate, using the torx was the best advice that worked a treat when my easy outs failed.....thanks mate you're a legend

[@rokyle2323]

Dude I watched this video and thought it was dumb but HOLY SHIT ITS SO EASY seriously your the real MVP this was the best trick ever

[@2carpros]

Thanks of watching! One of the things I picked up working these years. It is really handy to know.

[@glenglene8473]

you made it easy, but in real life, it can't e that simple. 9 out of 10, you will break the torque bit and you're screwed.

[@therealsideburnz]

One thing you need to watch for on the easy outs is that because of the way the spiral flutes draw the tool into the hole you can actually end up expanding the stud and jamming it even tighter. Been there, broke the easy out, got the t shirt

[@2carpros]

Oof that's rough bud. Thanks for watching!

[@tjmc2168]

Here because I just did this.

[@CarpaccioSalad]

Same bro... i just welded a fcking stud onto it hahah

[@jeremyrock9305]

Absolutely I never use easy outs they are hard as glass even good ones and break off then your screwed! Been there done that

[@chrisstromberg6527]

When it happens, get out your Dremel and a cheap diamond grinding bit. I don’t use the easy out any more for this.

[@watchfast1]

Size 2.5 hardened steel drill bit and T20 Torx bit. The punch is a narrow center punch. Use oil to dissipate the heat on the cutting edge of the drill bit. The right angle drill is 3/8”.

[@erixandercooper5563]

lol i gotta face the same task now!!

[@chasehamm2646]

This is what I was looking for. I wasn’t ready for it but it’s what needs to be done

[@connorcook3123]

i do the exact same, it has worked literally everything

[@JamieMurdock90]

Please drill slowly, with oil, and apply a lot of pressure. That keeps the bit cool and sharp. Then no special bits are needed.

[@leadweightguy6134]

Jamie A cheap bit will work like that? WD work for oil?

[@JamieMurdock90]

@@leadweightguy6134 This was taught to me by a 60 yr old finish carpenter and I found it very successful. WD-40 should work as both a lubricant and a conductor of heat, but it might evaporate under the high heat of a drill More easily than 3-in-1 oil or even drops of whatever motor oil you have. They drill bit that's rotating quickly on metal will get very hot and heat destroys anything. If a brand new, or very sharp drill bit is actually cutting the metal, and it's turning slowly and there is any kind of oil present, then the oil will conduct the heat and the high pressure and sharp edge of the drill bit will cut into the metal instead of spinning on top of it and getting super hot. So yes a sharp and cheap drill bit with whatever oil you have turning slowly should work but I am not deeply experienced on the topic.

[@348frank348]

i haven't even tried and I'm already thinking that all of them are going to break flush like this

[@mrmagneto554]

There is an AWESOME product called Liquid Wrench which I wish I had heard of BEFORE I snapped off my manifold bolts. Spray it on the night before, leave it overnight and then in the morning the rusty bolts will come right out, no troubles.

[@Manny0Rocket]

That wasnt a regular Torx socket. It was threaded!

[@348frank348]

@@mrmagneto554 thanks man i will give it a shot

[@kevinhancock4064]

@@mrmagneto554 I'll take a look thanks I've only managed to.get 2 out fully I now have 3 snapped 3 to go its a headache

[@I0ITuGI0I]

OMG, no way... You used to do PC tech unboxings with your friend right? there's no way!

[@andrewball6460]

This worked for me on a rear manifold, up in a tight spot. This goes in the top 10 most awesome tricks I've learned for sure.

[@2carpros]

NICE! Thanks for watching Andrew!

[@TheSailingwoodworker]

It would be nice if I had enough room to do this on my E250 van with the 4.6 modular V8.

[@ryansmotorsports2199]

What size torque bit did you use and what size drill bit did you use?

[@Kcducttaper1]

Hoping I can squeeze up in there and do this on my F-250's 5.4 and just replace the stud without taking the rest of the manifold off. I reallllly don't want to take that whole thing apart!

[@2carpros]

Good luck! Thanks for watching!

[@OGbqze]

Just broke 7 drill bits on the broken bolt in my head for my intake manifold bolt. Luckily I got it, but now I have a broken exhaust bolt that I need to remove. Fun.

[@SimbaAliaye]

My mechanic just found 2 broken exhaust manifold bolts in my 2003 GMC Yukon Denali. He said he didn't do those. That I'd most likely need to find some exhaust shop to do it. Called Mechanic B. He couldn't tell me on the phone if he could do it or not. I'll be swinging by on Monday to see what he says. What's the price difference between this job and disassembly?

[@Username-ng8jy]

Did you figure out the cost or did you do it yourself? I just ran into the same problem. Got all the bolts free till I noticed one missing and looked with a flash light and it’s broken inside my heads

[@jerrettbrown1845]

Thank you I was getting so pissed at that i tried everything to get them out they finally came out

[@2carpros]

Nice! Thanks for watching!

[@Sip28]

Wish you could get mine out😞

[@rican650]

This trick just saved my customer thousands of dollars. It was almost to easy. Thank you.

[@2carpros]

Great to hear! Thanks for watching!

[@IH8CA]

Thank you so much!!! This saved my butt on a 5.7 Hemi. Even with a special tool, couldn't get the right angle to drill clean. This worked perfectly, thanks!

[@2carpros]

Nice work! Thanks for watching!

[@Sidluvher]

Hey I gotta change my exhaust bolts on a hemi too does the video include all the info or is there anything you would suggest

[@IH8CA]

@@Sidluvher It just depends how badly the stud is broken. If it's broken inside the head, this video was perfect. If it's sticking out, just get a set of vice grips on it and back it out. It was intimidating at first, but i've done a few sets now for friends etc. and it's easy.

[@davidkettlewell829]

Super video, got an old 44 year old motorcycle to restore...came with one manifold exhaust collar bolt snapped off 1/2 into manifold. Considering options. I was thinking about drilling out an 8mm bolt so it can go in remaining threads, and pr0vide guide for 1/8th inch bit, then use that hole with extractor, or the torque socket you suggest. It is very easy for a drill to drift when drilling out center of a snapped bolt for reasons you cover. Thanks for this advice.

[@cooleydread3215]

Why not just use a magnetic to pick up the metal pieces around your engine

[@emuralles13]

Great video man worked like a charm!

[@2carpros]

Great to hear!

[@stevesmith-zf8dp]

I assure you if you have a bolt like this but its in the exahuast manifold and rust welded. Is not this easy.

[@ericrivera1524]

I was thinking the same thing... How did it snap off in the first place, but extracted so easily? I'm facing a similar problem, but my bolt snapped where the catalytic converter bolts to manifold...

[@richierex]

I agree with you. He was lucky

[@rickallen6378]

Looks like about a 5 yr old vehicle; can you show that on a 1972 farm truck?

[@vincentminer749]

So what happens when the ez out snaps inside of the bolt?

[@Austinthecarter17]

bust out the welder

[@themindofjohn4346]

Your bout screwed unless by a miracle you can remove it

[@zash008]

Cry...wipe eyes. Trade vehicle in on a new one. Cry some more.

[@antn8387]

DREMEL with carbide/diamond grinder

[@mikemaj8467]

The only reason this method makes me nervous is because if the bolt extractor breaks now you have a real problem as they are often hardened and cannot be drilled. I would definitely use the largest extractor that would work.

[@2carpros]

This usually works for me. If this failed you’d have to go to melting it out. Thanks for watching!

[@AMJB100000000]

Don’t do this with Chinese bits they’ll break off and you won’t be able to drill them out as they’re hardened steel... I’m fuked now

[@paulm1237]

Now a video for removing the hardened torx bit that broke off? Lol

[@thetruthmatters7]

Thanks very much! God bless you, and Jesus loves You!

[@2carpros]

Thank you for watching!

[@Sip28]

Did you get your bolts out?

[@RichardDavey-ry1vh]

I had to take the exhaust manifolds off to do the freeze plugs...ok

[@williamoliver6550]

Good job, but I cant believe you didnt block up the exhaust ports first! Not good practise to have swarf going in there mate

[@traviscarr6536]

That was my first thought. Don’t even know how I came upon this video. Evidently I’m bored at 2am.

[@nickdavis6294]

Midas wanted 450 to 2gs to remove a broken stud in the head.

[@2carpros]

2 grand?! Holy cow! Thanks for watching!

[@RichardDavey-ry1vh]

I will be getting a new drill press payday....ok

[@jimmybob7364]

Yeah maybe on an engine that looks like it only has 10k on it. Lmao.

[@josiah7068]

Boooooooo there is no guarantee that a stud will brake flat and the ability to DRILL STRAIT into broken stud nor will a center punch core t that ….further more you showed a idea situation with plenty of space for your demonstration …. Get to real world situations and. Then start making videos 🤨🤨🤨🤨

[@KenLavacot]

If it breaks at an angle, grind it flat, if you cant get to it, remove it or make room. If it breaks at an angle internally use a smaller drill at an angle and finesse it to the middle then use a larger drill. Have you removed many broken bolts? I have.

[@MilanPatel-ch1qu]

Awesome tip, I’ll try on my dang 6.2 Cadillac. It’s leaking from one side due to broken stud

[@2carpros]

You got this! Thanks for watching!

[@cameronbraun6265]

How did it workout? I have the exact same problem with my Cadillac and it looks too deep to weld.

[@scientist100]

@@cameronbraun6265 I think he paid a specialist because his internet was cut off due to the cost of that bolt to said specialist.

[@dr.floridaman4805]

Guys working on a catalytic converter is much cheaper than changing out your Cadillac.

[@GreenerExteriors]

If anyone doesn’t know yet, leave yourself a solid 2-4 hours after running the engine for the exhaust to cool off. You’ll burn yourself bad just touching neighboring components.

[@everyday80sdude86]

Now do rusty froze up bolts. 🤷‍♂

[@Rocksteady176]

Step 1) COVER THE EXHAUST PORT!!! Metal shavings in a cylinder do not mix very well...

[@Metaganondorf]

Can i get a like for the drill you used

[@funnyboy1368]

Great stuff man, legend for that

[@rayaustin2560]

NEVER use a torx bit...ONLY use the ez out. I wish I could post a picture of the broken HARDENED STEEL torx bit stuck in the hole I drilled. Try drilling the end of that torx bit. TERRIBLE IDEA BUDDY!!!! I know it probably worked for you but there is a chance it could break off then second chances are shot.

[@KenLavacot]

Have you ever broke an easy out? same problem hardened steel !! The idea it not to break it, I have been a mechanic for 35 years and a machinist for 20 this works the best. The torx bit grabs better

[@2carpros]

It has worked for us for multiple uses across generations. You can also break an ez out pretty easily and they are typically harden steel as well. So I'm really not seeing what you are saying. Thanks for watching!

[@miketavenermedia7853]

Thank you so much!!!! This one trick worked when everything else I tried failed (multiple times).

[@2carpros]

Glad it helped!

[@jrmuse1002]

Of course on an almost new engine as you have in front of you🤷‍♂️. Try that on a rusted 200k miles manifold. Not gonna happen

[@michaelpresey2273]

Ok and if your ez out or your torx bit snaps in the bolt how about that ? You're pretty much f****d and force to drill and tap a bigger hole lol

[@2carpros]

Or grab a torch, can't be tight if it's a liquid. Thanks for watching!

[@alaxandersupertramp6955]

What size bits?

[@RichardDavey-ry1vh]

You have to take the exhaust manifold off and get a drill press....start by drilling with a small drill bit first.....ok....and go a little bigger at a time....to get the stud out and use a easy out....if needed.....

[@Chevro91]

In real world situations most bolts that snap are rusted in severely That bolt was not even close too being rusted it’s likes brand new broken bolt just for show 😂

[@2carpros]

Nope, it was real. Thanks for watching!

[@HIREDGOON87]

Tried the EZ out and I could feel something was going to give, took it out and hammered the torx bit in there, had to put some pressure on it but nothing broke and the bolt came out. Even if you f-up a torx bit it is well worth it, replace it for $3, will save ez-outs for screws. Thanks for vid.

[@2carpros]

Agreed! Thanks for watching Robert!

[@fullthrottleproductions1449]

I broke my bit inside of the stud when removing any one know a good drill bit to drill threw a torqes bit lol

[@paulhamilton5634]

IF you happen to have a 90 angle drill andIF the bolt isn't the one in the back of a V8. And you should put a rag in the exhaust hole so you don't get chips in the cylinder.

[@scmiata99]

what was the torque socket?

[@rtg8point858]

I'm not buyin it! The bolt broke, BUT make a little hole, hammer a torx bit in and WALA! The bolt BROKE because it wouldn't turn to begin with but a torx bit works but the bolt head didn't? Yeh right.

[@2carpros]

I mean I showed it plain as day in the video. Once the head is snapped off you'd be surprised with how little the threads are held in. Thanks for watching!

[@danielcontreras976]

How do you know the bolt broken that way? Did you not watch the video?

[@moctarmama4630]

I’ve same issue but with side cover bolt on Honda accord 2012 the broken bolt located beside the VVT solenoid 😢 It’s difficult place and I don’t want to take the engine out to remove the broken bolt

[@ДмитрийИванович-о5ъ]

What you gonna do if you broke your torq socket inside??? I have this situation, I spent a lot of time, and without any success. Any advice would be appreciated..

[@2carpros]

Since it is an aluminum head, I'd wield a nut on and use a wrench to back it out. Works every time there is dissimilar metals. On an iron head you run the risk of welding to the head though. Thanks for watching!

[@ДмитрийИванович-о5ъ]

@@2carpros I tried, no success.

[@Elboricua316]

How do I remove the flex pipe screwthat breaks that coming down from the manifold

[@frednicholson]

Would be great to see an example with more rust. That looked pretty easy and the bolt was practically mint.

[@tylerparker3024]

Clearly not a very old bolt. Only reason you got it out that easy

[@2carpros]

11 Year old cop car with 175k miles. Decently old. Thanks for watching!

[@neillameier8644]

@@2carpros Try a 20+ year old jeep and get back to me.

[@Jake-im2lv]

@@neillameier8644 oh piss off

[@neillameier8644]

@@Jake-im2lv Want a tissue?

[@Jake-im2lv]

I just extracted a snapped manifold stud out of a 35 year old Celica with a drill and torx bit, so sod your 20+ year old Jeep and your gatekeeping attitude

[@garrettlamb9916]

Is there anyway you can tell me exactly what drill bit you used? I’ve bought and tried and melted and bought and broken and tried so many different ones! That bolt is hard!

[@CharlesHeckleberry3rd]

i definitely wouldnt be blowing metal chips straight at an open head

[@2carpros]

Valve was closed and we blow anything out but you can use a papertowel in the port to make sure. Thanks for watching!

[@mnoman2549]

You got lucky

[@josephthespeeddemon]

Cobalt won’t work? Lmao ok- cobalt is for hardened metals … lol

[@2carpros]

The ones I had didn't, is what I said. Thanks for watching!

[@sebestiensoliz8831]

Can this work on a Plenum screw that broke off?

[@2carpros]

Yep! Thanks for watching!

[@michaeld5664]

just did it myself today and it worked beautifully!!

[@2carpros]

Nice work! Thanks for watching!

[@robertporras5060]

Don’t use the bolt extraction tools cause they break fairly easily and you will be in a worse situation

[@hummertim1]

I would not recomend drilling out with easy out. the weld method is safer i learned the hard way. Doing it with easy out cost me two new heads if the bolt is seized in it take it to someone who can weld a nut on it to remove it or pay a few thousand dollers.

[@benking4367]

Looks like I have to go buy me a right angle drill , I have 4 dang studs broke off on my 5.4 triton, thanks man !!

[@adaleparker1956]

I'm having trouble drilling into my broken exhaust bolt. I started with a 1/8 inch bit and I used cutting oil but it isn't going in very well. Could recommend a drill be that would definitely cut into that more easily?????

[@Morningbikeride]

How do I find a replacement bolt for the header if I can't find it online due to being an old model? Hardware store?

[@leobarajas81]

Best tip yet worked like a charm on the first try thank you

[@NoahsArk4532]

Any idea what drill bits or what size? I should buy to drill out rusted/broken 2002 Honda Civic exhaust manifold bolts? Just wanna make sure I get the right kit or use the right size

[@yourit311]

What size bit and torque bit?

[@2carpros]

2.5 Hardened steel bit and a T20 Torx. Thanks for watching Shayne!

[@scottmoola2311]

Damn you made that look easy

[@2carpros]

Years of practice. Thanks for watching!

[@sacr3]

I've got a Hemi with a broken stud but the access is absolute hell. I need to wait a little bit and purchase myself a 90° angle drill.

[@2carpros]

Helpful tool! Thanks for watching!

[@Trohawkk]

lucky

[@2carpros]

I make my own luck. Thanks for watching!

[@ja-makin-me-fit7335]

Wow lmao this is amazing. Your manifold videos are the best! I've been watching a few and you are straight to the point with GREAT tips! Thank you!

[@UltimatumAutomotive]

Weld a nut. If you brake a tap or bit off ur screwed

[@2carpros]

I've never gotten the nut wield trick to work here because the thread is broken down in the threads. You'd prob fill the wield to the threads and lock it up worse. Also I'm not so sure you could get a wielder in this tight space. Thanks for watching!

[@streamer1598]

Nice and straight to the point. 3 👍 up

[@2carpros]

Thanks for watching!

[@NavcOMechanicaL]

Thank you! It just worked for me, to remove a broken stud on a 2012 GMC Terrain!

[@JorgeTorres-gv6hm]

That's an AWESOME IDEA thank you bro for sharing you knowledge

[@2carpros]

No problem 👍

[@texanwd8387]

All good until the torx bit breaks then almost impossible to drill out

[@richierex]

You have obviously ever used eze out as they don't work very well and if they snap then you are done. How about a bit of paper in the exhaust ports to stop all the buddy bits going in. Doh 🤔

[@zash008]

Ram 5.7 Hemi engines...constantly exhaust manifold bolts break

[@2carpros]

Which gen? My buddy has one and we were just talking about this. Thanks for watching!

[@doclockwood8841]

Dodge v8 exhaust studs are prone to snapping. Lotsa videos on them, but this is by far the easiest I've seen one come out, tho this is on a Ford block. One trick I've learned in my many years, to AVOID SNAPPING BOLTS IN THE 1ST PLACE, is to gently tighten the old bolt before trying to loosen it. This very often "cracks it forward" by just the tiniest fraction and often it unbinds the threads perfectly. Guess it's the surface rust of the bolt head, washers, etc. stuck against the block. Works about 80% of the time. Also, a little Master Blaster with a few taps of metal on metal and some patience works wonders, too. Let it work its way down the threads, maybe 15 minutes or so. Then crack it forward a little...success! I'd avoid air and power tools on broken studs, except when drilling, cuz I trust the "feel" when wrenching out wrecked threads, etc. but to each his own. Good luck.

[@doclockwood8841]

Also, put your own wheels and tires on, without an air wrench set at 200 lbs, like a lot of Walmarts and tire centers do. They crank the studs down and stretch the threads so if you DO have a flat, you'll snap one or two off on the side of the road. No fun. Use your own torque wrench for the last few threads and avoid snapped wheel studs. And never use thread lock on these wheel bolts. Gummy mess.

[@zash008]

@@doclockwood8841 who puts thread lock on wheel studs? I agree with not using it or Walmart to touch your vehicle for anything but If you have a gummy mess from using thread locker as in Loc-Tite then you are using it for the first time and using entirely too much in the first place of the stuff.

[@doclockwood8841]

@@zash008 I agree about Threadlock. A buddy helped change two of my tires out of my sight and thought he was doing me a favor by using Threadlock. Gummy mess. Got it all off, tho...back to clean threads.

[@DigitalRevolution0106]

how do you hammer in such tight space ?

[@mlez7197]

whats the angle drill atachment model # ?

[@randallsmith7022]

Well it was a good idea until it wasn’t my torx but broke and I don’t know what to use to drill through it.

[@mikesecondo2254]

WAIT!!!!....before you drill and blow metal chips into the head....shove a rag into the port ...TIP!!

[@2carpros]

Yeah avoid things going in the cylinder. Thanks for watching!

[@joeolsen3553]

Well, Bosch/DeWalt/Milwaukee drill bits broke - this job sucks - hardest bolt I ever seen - even sprayed oil on it while drilling. Will have to look for better drill bits FJB Gas prices, inflation, interest rates FJB

[@2carpros]

Yeah you have to have high quality hardened super sharp drill bits. Thanks for watching!

[@fatrustybagz4237]

I used an easy out and I snapped it

[@2carpros]

Talent! Time to melt it out. Thanks for watching!

[@Jake-lx2xs]

What exact brand of drill bit is best please

[@chrisstromberg6527]

Stay tuned for are next video, how to use a diamond bit grinder to remove your broken “easy out” or “torx bit”. 😂 Great video none the less!

[@WicKedwiNd91]

Naaah that ain’t real life lol.

[@2carpros]

It is I promise! Thanks for watching!

[@seeforyourself7841]

Your comment about Cobalt drill bits is kind of confusing. Unless you mean Kobalt the brand. Cobalt is generally considered harder i.e. stronger than Titanium...

[@2carpros]

I had Cobalt Kobalt drill bits and they were terrible. I just like my titanium ones. Thanks for watching!

[@Battleaxegunner]

Tyvm for this video. I snapped a stud on one of my exhaust flanges that was on the passenger side catalytic converter while preparing to install a new Y-pipe. Omg, your the guy from LavcoPriceTech! What happened to the channel?!

[@2carpros]

So glad this helped you! That's not a channel I have thought about in years. Price and I agreed that it was best if we moved on. Thanks for watching!

[@ignacioromero5014]

its amazing what some people call hard work haha... Try roofing in July in Phoenix AZ

[@2carpros]

That sounds hot. Thanks for watching!

[@KevinGomez-ew8nn]

This just saved my life , thank you very much !!!! I was panicking for a quick second haha

[@2carpros]

Awesome! Thanks for watching!

[@hughjazzole2037]

i IMAGINE ALSO IT WOULD BE GOOD TO SPRAY SOME LUBE IN THERE? TO LOOSEN ALSO i HAVE TO TRY THIS MY 93-945 HAS TWO BROKEN #4 STUDS..

[@2carpros]

Maybe it would help? But in our situation gravity was working against us. Thanks for watching!

[@stephennoe9762]

if only it was that easy

[@nickolico]

Excellent! Thank you. My wife says “this guy seems nice”

[@2carpros]

Thanks for watching!

[@kevinhancock4064]

Yrah I'd like 4 u to take mine out thus easy I have these tools ill give it a try but I'm doubtful aka 14+ years motorcycle header bolts 3 snapped

[@2carpros]

Worth a try! Thanks for watching!

[@dexgsand]

Nice vid… but i broke my torx n its still stuck!!!! DAMN IT.

[@2carpros]

Bummer! Well the next step is to grab a torch. Can't be stuck if it's a liquid. BE CAREFUL THOUGH. Thanks for watching!

[@robpaul7900]

Seems like this hardly ever turns out going this smooth when you have a broken off bolt

[@2carpros]

This stud broken off is basically the same thing. Thanks for watching!