Exhaust collector bolts broken off in manifold

[pat]

I finally replaced my slipping 700r4 in my 89 Jimmy last weekend. Pretty much everything screwed up along the way, but I got it almost done.
As my luck would have it, I broke off 3(1 on the driver, 2 on the passenger side) bolts that hold the exhaust onto the manifolds. I figured the 2 bolts would be good enough for me on the drivers side, so I went out to pull the manifold off of the same 350 we had lying around, and it had 2 bolts broken off in it too.
Is there an easy solution to this?
The only thing I could think of was to cut a couple small pieces of metal about 2 inches long or so and drill holes in both ends, then use that as a clamp kinda. It would be ugly, but I dont care.
And wow, that NP203 is hea-vy.

[89 crew]

It depends on where it broke on how easy it is! If it broke off flush with the manifold go to a junk yard. it will be the easiest! If there is stud sticking out take a nut that will barely fit on the remainder of the stud and weld it there. let it cool, then heat the manifold till it is cherry red around the stud, then unscrew it.

[Dooley]

Take the manifolds to your local Midas or other experienced muffler shop. Those fellows have a ton of experience at removing broken studs and all the right tools.

[Slonaker]

One of the studs on one of my Chevies, I can't remember which, has been drilled out and replaced with a bolt by a previous owner. It is put in from above through an oversized hole. It sticks out the same distance as the stud did, and is the same size. It works fine.

If you can't weld, and don't want to use a bolt, the junkyard is the easiest route. If you want to go new, rockauto.com has aftermarket manifolds for reasonable prices. I have never used them before, but always hear good things about them. Shipping might be hiigh on something made of cast iron.

Slonaker

[killthewabbit]

I know it's not much consolation, but I've never not broken an exhaust manifold stud the first time I've touched it. Every single one I've touched, from 69 Chevelle to 94 S10 have all broken off. I think the heat cycles they're subject to make them brittle. I've always ended up switching to headers.

Probably not what you wanted to hear, was it? Sorry about that.

[pat]

Originally Posted by killthewabbit

I know it's not much consolation, but I've never not broken an exhaust manifold stud the first time I've touched it. Every single one I've touched, from 69 Chevelle to 94 S10 have all broken off. I think the heat cycles they're subject to make them brittle. I've always ended up switching to headers.

Probably not what you wanted to hear, was it? Sorry about that.

Hey, at least Im doing better than you, 3 out of 6 so far!

[killthewabbit]

Let me rephrase - I've always broken off at least one on every car I've tried to remove the exhaust from.

Not really much better, but I haven't broken absolutely everything I've ever touched. Feels that way a lot, though.

[pat]

Originally Posted by killthewabbit

Let me rephrase - I've always broken off at least one on every car I've tried to remove the exhaust from.

Not really much better, but I haven't broken absolutely everything I've ever touched. Feels that way a lot, though.

I know how you feel.

[slepysal]

Originally Posted by Dooley

Take the manifolds to your local Midas or other experienced muffler shop. Those fellows have a ton of experience at removing broken studs and all the right tools.

Midas and experienced don't go together were I'm from. JK
But I agree any good mufler shop should be able to help you.Or you can use this as an excuse to get some headers !!

[1984Silverado4x4]

I busted off 2 of those studs on my brothers 84 Chevy. I just took the manifolds out put them in a vise and drilled out the studs then got a tap to fit the same size as the old stud and retapped it. It was a lot easier then I thought it would be.

[89 crew]

If you want to prevent this from happening again throw away the steel nuts and replace them with brass.

[SBTork]

Originally Posted by 89 crew

If you want to prevent this from happening again throw away the steel nuts and replace them with brass.

a very good idea

[bb1979]

Pull the manifolds and take them to the exhaust shop it should be less than a 10 minute job for them............... brass nuts = very good idea.

[Mickey_D]

Personally I don't even bother trying to take the nuts off when I'm pulling the exhaust off the manifolds. I just grab the end of the stud with a pair of vise grips and tap the studs out with a hammer from the manifold that way, then go get new ones from Chevy.

Yes, a little more expensive, but well worth it when you go to put it back together and you're not having to hold up the pipe while trying to screw a rusted nut onto a deformed stud...