Rusted bolts... - The 1947 - Present Chevrolet & GMC Truck Message Board Network

Andy4639 · 01-14-2018, 10:11 AM

I worked on the ramp truck yesterday for a while and was wondering what to do.

Exhaust manifold bolt heads are so rusty that I had no sockets either standard, mm that would fit them. I even tried hammering on smaller sockets that just twisted off the head even more.
What do you guy's suggest? I soaked them down good with Kroil also but I'm telling you they are rusted bad.
I almost took my small hammer to them to crack them off but decided not to!I need to get them off to install the new ones that I got because these each have a stud broke off.

I went last night and got a set of these last night going to try today I hope.

**BlueBullet** · 01-14-2018, 10:27 AM

If you have access you could try cleaning up and weld a new nut on. Better grip and heat might loosen things up.

67swb72klb · 01-14-2018, 10:37 AM

You didn't say anything about heat That will help tons Maap gas at least

Andy4639 · 01-14-2018, 12:06 PM

No heat but I can try that as well. May crank it up and let it warm up good and start on it see what happens.

**twouvakind** · 01-14-2018, 12:17 PM

Heat as in Cherry red, maybe a baby oxy fuel setup from Home Cheapo?

faribran · 01-14-2018, 12:18 PM

Heat/welder is my choice

Mike C · 01-14-2018, 12:54 PM

Do you have an impact driver? The one you hit with a hammer style. Cut a flat head groove in the bolt head and hammer with impact driver. The hammering action usually loosens any lightly struck threads.

Theoretically... exhaust manifold bolts are not bottomed in the head so when the head is cut off and the manifold removed (if you have room...) they should be loose enough to vise grip them off.

**Ironangel** · 01-14-2018, 12:59 PM

Heating the heads wont do a thing for the stuck thread shanks...Soak them with Kroil or the trans fluid acetone elixir and then fire the motor up. Let it get good and warm and hit the head of the bolts with a hammer, that helps crack them loose. Put the best fitting six point socket on them and rock them loose. Use a tightening loosening method until they crack loose. You may have to do this two or three times to get them out. Mike C's method will work as a last alternative but you'll have to raise the motor to clear the frame rails...

Andy4639 · 01-14-2018, 09:16 PM

My day was a no go!
Wifes ex boss passed away so we spent the day at the funeral home.
Hopefully in the next couple of weeks. Next week is beach trip for her birthday.

**clay68c10** · 01-14-2018, 09:32 PM

Keep soaking them with kroil all that time. It’ll soak in, that stuff is the cats meow.

Andy4639 · 01-15-2018, 07:03 AM

Quote:

Originally Posted by clay68c10

Keep soaking them with kroil all that time. It’ll soak in, that stuff is the cats meow.

Yep it's all we use at work. It has worked great for me in the past.

**bigmac73** · 01-15-2018, 09:47 AM

soak the piss out of them and try a small pipe wrench(grip tight) and a hammer, If I was going to pull the heads I would just cut off the bolt heads to remove the manifold (if you have room against the frame rail) and then get the head on a workbench or a machine shop to work removing the rest of the "studs" instead of chancing breaking them off at the threads in the head, if that happens you are back to the pull the head to fix idea anyway.

Andy4639 · 01-15-2018, 07:12 PM

Quote:

Originally Posted by bigmac73

soak the piss out of them and try a small pipe wrench(grip tight) and a hammer, If I was going to pull the heads I would just cut off the bolt heads to remove the manifold (if you have room against the frame rail) and then get the head on a workbench or a machine shop to work removing the rest of the "studs" instead of chancing breaking them off at the threads in the head, if that happens you are back to the pull the head to fix idea anyway.

Not pulling the heads just the manifolds. They both have one stud broke off so I can't tighten the exhaust up good. I got another set with good studs to replace them with. I'll be buying new bolts as well.

Aberdare · 01-16-2018, 01:04 AM

HEAT... the only way those puppies are going to come off. only an Snowballs chance in hell of getting them off any other way... just pray to the GOD that the studs don't break off leaving you with the added pain of having to extract them.

**Ironangel** · 01-16-2018, 08:55 AM

Heating those bolt heads will do nothing more than anneal their temper,(softening the steel) thus making them more susceptible to twisting off...Heating the head will expand the cast iron around the bolt thus momentarily reliving some of the grip and allowing the Kroil to work it's magic. Hitting the bolt head into the head will help crack it loose and allow the Kroil to creep...If you have an infra-red temp gun it can come in handy, heres how. This how "I" would do it...Drain the coolant, get your hammer and extraction tools ready with a pair of gloves...Fire that motor up with no coolant in the heads and monitor the heat with the infra-red...When you read 250 degrees adjacent to a plug, shut the motor down and go to work...If that dont work the first time, soak em down, let the heads cool, wrap/hit the bolts and do it again. They will come out, just have to be smarter than that bolt!

GRX · 01-16-2018, 11:50 AM

Cut the bolt heads off with a torch. Fair chance the manifold will slide off afterward. Then you have long shanks to work with. I would suggest one of these along with heat.

toolboxchev · 01-16-2018, 02:24 PM

I use a propane torch, or plumber's torch if you will. They are inexpensive plus you do not have to worry about overheating and annealing.

Once hot, I use a cold water hose to shock the metal. You can literally hear the bonded rust breaking apart. The use of Kroil and or PB Blaster for an overnight soak will help also.

palallin · 01-16-2018, 10:17 PM

Is there enough room to get a nut splitter on them?

midniteblues · 01-17-2018, 08:26 AM

I have had luck with welding a washer too the bolt head as much as you can then weld a flanged nut too the washer let the weld cool then have at it quickly.

I just had to do this on my cobalt with a broken exhaust stud that was below the aluminum head surface. Laying across the engine with a mirror clamped too the firewall watching my weld through that. 4 tries before I got that bugger out.

Andy4639 · 01-17-2018, 08:48 AM

Thanks for the suggestions guy's. It's going to be a couple weeks before I can get back to it. Have plans for this weekend and it's snowing here now so it maybe awhile before I try it again.
This should give me time to clean up the set I got to replace them with as well.

01-14-2018, 10:11 AM	#1
Andy4639 Old member Join Date: Jan 2002 Location: Liberty, & Garden City S.C. , U.S. Posts: 19,945	Rusted bolts... I worked on the ramp truck yesterday for a while and was wondering what to do. Exhaust manifold bolt heads are so rusty that I had no sockets either standard, mm that would fit them. I even tried hammering on smaller sockets that just twisted off the head even more. What do you guy's suggest? I soaked them down good with Kroil also but I'm telling you they are rusted bad. I almost took my small hammer to them to crack them off but decided not to!I need to get them off to install the new ones that I got because these each have a stud broke off. I went last night and got a set of these last night going to try today I hope. __________________ 1971 LWB Custom, 6.0LS & 4L80E, Speedhut.com GPS speedometer & gauges with A/C. 20" Boss 338's Grey wheels 4 wheel disc brakes. My Driver Seeing the USA in a 71 Upstate SC GM Truck Club 2013,14 and 2016 Hot Rod Pour Tour http://upstategmtrucks.com/ Get out and drive the truck this summer and have some fun! It sucks not being able to hear! LWB trucks rule, if you don't think so measure your SWB! After talking to tech support at Air Lift I have found out that the kit I need is 60811. Per the measurements I gave them. Ride height of truck inside spring and inside diameter of springs.

01-14-2018, 10:27 AM	#2
BlueBullet Senior Member Join Date: Apr 2013 Location: Danvers Minnesota Posts: 967	Re: Rusted bolts... If you have access you could try cleaning up and weld a new nut on. Better grip and heat might loosen things up. __________________ 1972 K10 SWB wife's driver 1967 Pontiac GTO Big Bird - 1972 Longhorn K30 http://67-72chevytrucks.com/vboard/s...d.php?t=753294

01-14-2018, 10:37 AM	#3
67swb72klb Registered User Join Date: Dec 2010 Location: livingston co.mi Posts: 2,470	Re: Rusted bolts... You didn't say anything about heat That will help tons Maap gas at least __________________ California 65 GTO---Texas 64 burb 283 ---Oklahoma 67 CST SWB BBW wood bed 327 2004r---New Mexico 72 k10 350 350 auto---Georga 72 short step project

01-14-2018, 12:06 PM	#4
Andy4639 Old member Join Date: Jan 2002 Location: Liberty, & Garden City S.C. , U.S. Posts: 19,945	Re: Rusted bolts... No heat but I can try that as well. May crank it up and let it warm up good and start on it see what happens. __________________ 1971 LWB Custom, 6.0LS & 4L80E, Speedhut.com GPS speedometer & gauges with A/C. 20" Boss 338's Grey wheels 4 wheel disc brakes. My Driver Seeing the USA in a 71 Upstate SC GM Truck Club 2013,14 and 2016 Hot Rod Pour Tour http://upstategmtrucks.com/ Get out and drive the truck this summer and have some fun! It sucks not being able to hear! LWB trucks rule, if you don't think so measure your SWB! After talking to tech support at Air Lift I have found out that the kit I need is 60811. Per the measurements I gave them. Ride height of truck inside spring and inside diameter of springs.

01-14-2018, 12:17 PM	#5
twouvakind Senior Member Join Date: Dec 2011 Location: South Carolina Posts: 2,662	Re: Rusted bolts... Heat as in Cherry red, maybe a baby oxy fuel setup from Home Cheapo?

01-14-2018, 12:18 PM	#6
faribran Registered User Join Date: Jul 2005 Location: AL Posts: 1,828	Re: Rusted bolts... Heat/welder is my choice __________________ "

01-14-2018, 12:54 PM	#7
Mike C Registered User Join Date: Dec 1999 Location: Austin, TX, USA Posts: 7,727	Re: Rusted bolts... Do you have an impact driver? The one you hit with a hammer style. Cut a flat head groove in the bolt head and hammer with impact driver. The hammering action usually loosens any lightly struck threads. Theoretically... exhaust manifold bolts are not bottomed in the head so when the head is cut off and the manifold removed (if you have room...) they should be loose enough to vise grip them off. __________________ 44 Willys MB 52 M38A1 64 Corvette Coupe 68 Camaro 'vert LT1 & TH700 69 Z/28 355 12.6's @110 69 Chevy Short Step 4 1/2"/7" drop 72 Jimmy 4WD 4spd 4" & 35's 02 GMC 2500HD 4x4 Duramax

01-14-2018, 12:59 PM	#8
Ironangel Senior Member Join Date: Feb 2010 Location: Falls City, Nebraska "100 Miles From Nowhere" Posts: 2,219	Re: Rusted bolts... Heating the heads wont do a thing for the stuck thread shanks...Soak them with Kroil or the trans fluid acetone elixir and then fire the motor up. Let it get good and warm and hit the head of the bolts with a hammer, that helps crack them loose. Put the best fitting six point socket on them and rock them loose. Use a tightening loosening method until they crack loose. You may have to do this two or three times to get them out. Mike C's method will work as a last alternative but you'll have to raise the motor to clear the frame rails... __________________ Michael of the clan Hill, "Two Seventy Two's" 71 1-ton Dually 350 4-Speed 71 C/50 Grain Truck, 350 Split-Axle 4-Speed 02 3/4 ton Express 14 Indian Chief Vintage 1952 Ford 8N, "Only Ford Allowed On The Property" "Be American, Buy American"

01-14-2018, 09:16 PM	#9
Andy4639 Old member Join Date: Jan 2002 Location: Liberty, & Garden City S.C. , U.S. Posts: 19,945	Re: Rusted bolts... My day was a no go! Wifes ex boss passed away so we spent the day at the funeral home. Hopefully in the next couple of weeks. Next week is beach trip for her birthday. __________________ 1971 LWB Custom, 6.0LS & 4L80E, Speedhut.com GPS speedometer & gauges with A/C. 20" Boss 338's Grey wheels 4 wheel disc brakes. My Driver Seeing the USA in a 71 Upstate SC GM Truck Club 2013,14 and 2016 Hot Rod Pour Tour http://upstategmtrucks.com/ Get out and drive the truck this summer and have some fun! It sucks not being able to hear! LWB trucks rule, if you don't think so measure your SWB! After talking to tech support at Air Lift I have found out that the kit I need is 60811. Per the measurements I gave them. Ride height of truck inside spring and inside diameter of springs.

01-14-2018, 09:32 PM	#10
clay68c10 Senior Member Join Date: Aug 2004 Location: Centennial, CO Posts: 2,988	Re: Rusted bolts... Keep soaking them with kroil all that time. It’ll soak in, that stuff is the cats meow. __________________ ClusterTruck: 68 C10 Bought in 89, wrecked in 03. Slow low $ rebuild started '17. 6.0 & TKO http://67-72chevytrucks.com/vboard/s...d.php?t=788602 93 K1500 Short Step, 350, NV4500, EBL flash ECU. Vortec heads & roller cam someday... 05 Jeep Wrangler Unlimited. 3” lift & 6-speed 02 E320 the insurance total “free car” 13 Tahoe LTZ

01-15-2018, 09:47 AM	#12
bigmac73 Senior Member Join Date: Mar 2012 Location: Chesapeake, Va Posts: 1,275	Re: Rusted bolts... soak the piss out of them and try a small pipe wrench(grip tight) and a hammer, If I was going to pull the heads I would just cut off the bolt heads to remove the manifold (if you have room against the frame rail) and then get the head on a workbench or a machine shop to work removing the rest of the "studs" instead of chancing breaking them off at the threads in the head, if that happens you are back to the pull the head to fix idea anyway. __________________ Mike 72 C-10 Cheyenne off frame resto and Upgraded to 4 wheel disk, Tilt, Dakota Digital Dash / Rear slider. 421 SBC / TH350 3000RPM Stall Progression Ignition /Holley 750 DP/3:73 gear Eaton Limited Slip unit / 2 1/2 exhaust glasspacks

01-16-2018, 01:04 AM	#14
Aberdare Registered User Join Date: Oct 2017 Location: Manitoba, Canada Posts: 141	Re: Rusted bolts... HEAT... the only way those puppies are going to come off. only an Snowballs chance in hell of getting them off any other way... just pray to the GOD that the studs don't break off leaving you with the added pain of having to extract them. __________________ RED SEAL CERTIFIED JOURNEYMAN SINCE 1993 My 1966 GMC Value Van Project 1951 GMC 9430 1-Ton I'm just going to put an OUT-OF-ORDER sign on my forehead... and call it a day.

01-16-2018, 08:55 AM	#15
Ironangel Senior Member Join Date: Feb 2010 Location: Falls City, Nebraska "100 Miles From Nowhere" Posts: 2,219	Re: Rusted bolts... Heating those bolt heads will do nothing more than anneal their temper,(softening the steel) thus making them more susceptible to twisting off...Heating the head will expand the cast iron around the bolt thus momentarily reliving some of the grip and allowing the Kroil to work it's magic. Hitting the bolt head into the head will help crack it loose and allow the Kroil to creep...If you have an infra-red temp gun it can come in handy, heres how. This how "I" would do it...Drain the coolant, get your hammer and extraction tools ready with a pair of gloves...Fire that motor up with no coolant in the heads and monitor the heat with the infra-red...When you read 250 degrees adjacent to a plug, shut the motor down and go to work...If that dont work the first time, soak em down, let the heads cool, wrap/hit the bolts and do it again. They will come out, just have to be smarter than that bolt! __________________ Michael of the clan Hill, "Two Seventy Two's" 71 1-ton Dually 350 4-Speed 71 C/50 Grain Truck, 350 Split-Axle 4-Speed 02 3/4 ton Express 14 Indian Chief Vintage 1952 Ford 8N, "Only Ford Allowed On The Property" "Be American, Buy American"

01-16-2018, 11:50 AM	#16
GRX Registered User Join Date: Jul 2010 Location: MD Posts: 1,937	Re: Rusted bolts... Cut the bolt heads off with a torch. Fair chance the manifold will slide off afterward. Then you have long shanks to work with. I would suggest one of these along with heat. __________________ 1969 c-10 Step Side Long Bed. I-6 250cid = = 1969 Pontiac GTO hard top. 400, 4-speed.

01-16-2018, 02:24 PM	#17
toolboxchev Registered User Join Date: Jul 2015 Location: 2nd left past the stump on a dirt road. Posts: 2,629	Re: Rusted bolts... I use a propane torch, or plumber's torch if you will. They are inexpensive plus you do not have to worry about overheating and annealing. Once hot, I use a cold water hose to shock the metal. You can literally hear the bonded rust breaking apart. The use of Kroil and or PB Blaster for an overnight soak will help also.



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01-16-2018, 10:17 PM	#18
palallin Registered User Join Date: Jul 2002 Location: St. James, MO Posts: 1,238	Re: Rusted bolts... Is there enough room to get a nut splitter on them? __________________ '69 Longstep K-10: 327/SM465/T-221/Closed Knuckle Dana44/12-bolt.

01-17-2018, 08:26 AM	#19
midniteblues Registered User Join Date: Jul 2011 Location: strausstown pa Posts: 3,394	Re: Rusted bolts... I have had luck with welding a washer too the bolt head as much as you can then weld a flanged nut too the washer let the weld cool then have at it quickly. I just had to do this on my cobalt with a broken exhaust stud that was below the aluminum head surface. Laying across the engine with a mirror clamped too the firewall watching my weld through that. 4 tries before I got that bugger out. __________________ 81 camaro 355 4/spd 342 posi my first love. 67 swb step 454/4spd ott 373 posi 4/7 drop. 2000 s10 zr2 little blue truck that never gets stuck. '74 heald super bronc vt8. tecumseh powered moon rover.

01-17-2018, 08:48 AM	#20
Andy4639 Old member Join Date: Jan 2002 Location: Liberty, & Garden City S.C. , U.S. Posts: 19,945	Re: Rusted bolts... Thanks for the suggestions guy's. It's going to be a couple weeks before I can get back to it. Have plans for this weekend and it's snowing here now so it maybe awhile before I try it again. This should give me time to clean up the set I got to replace them with as well. __________________ 1971 LWB Custom, 6.0LS & 4L80E, Speedhut.com GPS speedometer & gauges with A/C. 20" Boss 338's Grey wheels 4 wheel disc brakes. My Driver Seeing the USA in a 71 Upstate SC GM Truck Club 2013,14 and 2016 Hot Rod Pour Tour http://upstategmtrucks.com/ Get out and drive the truck this summer and have some fun! It sucks not being able to hear! LWB trucks rule, if you don't think so measure your SWB! After talking to tech support at Air Lift I have found out that the kit I need is 60811. Per the measurements I gave them. Ride height of truck inside spring and inside diameter of springs.

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