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exhaust leak fix suggestions

Discussion in 'Chevy Silverado Forum (GMC Sierra)' started by texas99lb, Jul 20, 2009.

  1. texas99lb

    texas99lb New Member

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    hello guys, I have a pretty bad exhaust leak coming from my drivers side header. The last two bolts that attach the header to the head have broke off inside the head, I am pretty experienced with extracting bolts out of motors, but this one is a little bit more complicated, I am used to using a drill to drill a whole in the bolts and using an extractor to get it out, but my drill will not fit in the space givin, I was wondering what you guys would suggest I do to get these two bolts out so I can have a regular sounding truck..lol..right now its sounds like a really loud valve tick. I have attached a pic


    last two header bolts are broke off inside head by firewall
    [​IMG]

    any help is much appreciated
    #1
  2. morgan320i

    morgan320i New Member

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    thats a dirty engine :p lol i have the exact same problem i tryed to get a tap in there no way it would fit
    #2
  3. Mean_Green_95

    Mean_Green_95 New Member

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    try taking the manifold off and using some PB Blaster, a heat gun, and a set of vice grips to work the bolt lose.
    #3
  4. morgan320i

    morgan320i New Member

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    i belive he posted like mine is also its broken off inside the head
    #4
  5. morgan320i

    morgan320i New Member

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    vise grips cant touch it
    #5
  6. texas99lb

    texas99lb New Member

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    I know when I opened the hood when I bought it I almost cried it was so filthy. Yeah the vice grip approach will not work they are about a 1/8" inside the head..I want to clean the motor but dont want to pressure wash it for the fear of messing up my electronics, I have heard steam cleaning works ok. I have plan on cleaning it but dont know how to or what to use. I guess a little elbow grease.

    Have my eyes set on this..
    [​IMG]
    [​IMG]
    I just dont have 2300 dollars for it right now...
    #6
  7. Mean_Green_95

    Mean_Green_95 New Member

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    the vice grips couldn't touch it if you removed the manifolds?
    #7
  8. vncj96

    vncj96 New Member

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    if there is a jagged edge get a fine point punch and a hammer and try tapping the edge to unscrew it
    #8
  9. morgan320i

    morgan320i New Member

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    my truck was the oposite had some dings here and there a mest up tailgate some ugly rims and tires but the motor was spotless i never have seen a used motor as clean as it was
    #9
  10. texas99lb

    texas99lb New Member

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    Yeah I didnt get that lucky, this truck was used as an oil rig truck, so it was out in dirt all day, the body is in decent shape, there is a couple dings on it, but pretty clean other than that...I cleaned it up pretty good when I got it..The mud under the truck in pretty disturbing, but that will be taking care of. I guess my best bet with this issue is to either lift the motor so I have clearence or find a tiny angled drill that will fit in the given space, i have found one at a harbor freight tool store, I guess it is worth a try. Ill return it if it doesnt work. I really just dont want to have to take out the motor or remove the head for 2 damn broken studs, but the ticking noise is pretty annoying and I am sure my gas mileage isnt as good if it would fixed. I am willing to hear any other suggestions..Although I did get 600 miles to a full tank, I dont know if that is normal, but I was pleased..Filled it up from E for 75 bucks..
    #10
  11. morgan320i

    morgan320i New Member

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    i know what you mean sounds horrible i cant stand it. try to take off the manifold and maybe one of these [ame="http://www.amazon.com/EazyPower-73610-7-1-Flex-Extension/dp/B00004Z063"]Amazon.com: EazyPower #73610 7-1/2" Flex Extension: Home Improvement[/ame]
    and tell me if it works lol
    #11
  12. texas99lb

    texas99lb New Member

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    Thanks for the suggestion, but these are the bits that I have
    [​IMG]
    and the 1/4" nut drive end I dont think would work with my bit...If i could find something like that, I think that would work. Thanks for your efforts of looking for me, I really appreciate that..
    #12
  13. texas99lb

    texas99lb New Member

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    I am just thinking I am going to have to bite the bullet and lift my motor and do it that way...I just hope I can unbolt the motor mounts and remove the radiator hoses to have enough clearence..The brake booster is kind of in the way too..I really dont want to have unbolt the tranny from the block..but I dont want to the damage the driveshaft or tranny mount or anything like that..
    #13
  14. Rick from minnesota

    Rick from minnesota New Member

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    believe it or not this is actually an easy fix!! i've got a 2004 z71 suburban with the same problem and i found an easy bolt bracket that remedies this common GM issue and i consider myself only somewhat mechanical. i made the repair over a year ago and to this day have had no issues. i HIGHLY recommend this bracket for the simple fact alone that there was not drilling or extracting it simply bolts on and puts the precise supplemental pressure to the troubled area!! i've also just ordered a bracket for the passenger side on my neighbors newer gm truck and i'm expecting the same simplicity and results this "original exhaust bracket" is amazing!!!! the website is www.kralautoparts.com good luck and enjoy your results!
    #14
  15. 1BadV6

    1BadV6 New Member

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    Done many of these, with the right tools there not hard. You'll need a small right angle drill, good drill bit that your not afraid to ruin and a bolt extractor like pictured in previous post above, the right angle drill will fit with the manifold off but you many have to shorten the drill bit to fit within the space. Once you have a pilot hole drilled the extractor will usually take the remaining part of the bolt out. I've had a lot of luck with a left handed drill bit biting into the bolt and spinning the bolt out while trying to drill it.
    #15
  16. poncho62

    poncho62 Member

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    Take the manifold off.....If the bolt is just flush, you may be able to weld a nut to it and turn it out....If not, you may have to remove the head.
    #16
  17. j cat

    j cat Active Member

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    if a bolt is broken using a 90 deg power drill with REVERSE DRILL BIT. using the exhaust manifold to hold/guide the drill bit,, reverse drill the broken stud. using cutting oil for lube and not with much pressure , let the bit do the work. the stud should pull out .if not then you would have to remove the manifold but using the manifold to position the drill bit works best. I will use a small drill bit . place a PIECE OF METAL TUBING IN THE MANIFOLD bolt hole. then drill it out.this makes sure your in the exact center of the broken bolt.

    using bolt extractors these can make the stud harder to remove . these will make the stud get tighter in the threaded hole if the extractor is in the threaded portion of the head.

    when using the reverse drill bit these act like extractors but do not make the stud tighter.
    #17

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