6.0l removal/broken exhaust bolts

**bucknasty** · 11-01-2009, 05:26 PM

Huge problem.....! I went to put headers on my truck the other day when I got in there to take the old manifolds off I found that there is a broken bolt on both back sides of the motor and one in the front drivers side. I cant fit a 90 degree drill in there to drill them out or even see what I am doing. This is in a 2001 chevrolet silverado 1500HD with the 6.0L in it. If any one has any ideas on how to drill them out let me know. I have pretty much got everything undone to pull the motor except one bell housing bolt on the top drivers side.. How do I get that out??? if anyone can help me with this problem i would appreciate it..

**unplugged** · 11-01-2009, 05:42 PM

Is there anything at all sticking above the surface of the cylinder head?

If so you'll need the talents of a good welder. I broke a bellhousing bolt off and then I broke an extractor trying to remove it. I had the benefit of the engine being out of the car. There wasn't enough to grab with vise grips, so I took it to a welder who gingerly tacked a bolt onto the very small stub that was sticking above the surface. On the second try the bolt backed out with a gentle twist. Could be the heat from the arc welder helped "loosen" the bolt.

Otherwise you'll have to consider lifting the engine high enough to get access for the usual tools.
You could also consider some creative sheet metal modification. Seems to me there was a model of the Rolls/Bently that had holes in the fenderwell to allow access to the rear spark plugs.

If the heads have to come off, you may just want to take it to a machine shop that has an EDM machine. They can burn the bolt/stud out without damage to the threads.

**bucknasty** · 11-15-2009, 06:15 PM

All bolts were broken off at least an 1/8th of an inch inside the heads.. Instead of taking my motor to a mechanic and paying $300 for him to drill out the bolts I pulled the motor.. the easy way I found it was to pull the intake manifold off in order to reach the bellhousing bolt that is on TDC of the motor. Drilled the bolts out replaced the water pump gasket new intake gasket put it all together with my new headers and she runs like a dream..