Front and Rear studs broken both sides, (I think they're actually bolts)
Sounds nasty, as you can imagine.

Removing heads only way to get access to drill them out?
Head R&R doesn't look too bad- except for the exhaust, LoL

Do they make higher quality bolts/Stud sets?

Thanks in advance

'03 Express 3500 6.0

 

Im sure there are better bolts out there but this is a common problem on higher mileage LS engines due to the repeated expansion and contraction of the metal with the engine getting hot then cooling down after being shut off. I have worked around this issue on my LS powered vehicles by buy new GM bolts (just 4) and replacing the front and rear bolt on each side about every 5 years before they break. Of course this does not help you remove them if they are already broken. some exhaust shops can use a welder to build up the bolt and remove them but not sure if there is enough room in the van platform. Would need to ask.

 

Thanks, yes, that makes sense

 

+1 for welding nuts onto the broken studs...any shop who wants to drill ....get out of there before they damage the heads or charge a fortune due to how long it takes. Weld method is fast and safe.

 

Thanks. They aren't all broken flush w the mani-
So it would be near impossible to get a bead of weld on it.
You're right, it would also be next to impossible to drill, and if drilled, to get it out.

No shop would touch it w a 10' pole, LoL

 

welding is the best method for broken flush with the manifold. weld thru a nut onto the stud and build it back to the nut. since the head is aluminum the weld only penetrates the stud. anything above the manifold....stud extractors work well.
for pu we charge 1.5 hours per side plus extraction time. On my best days i can do the trucks in 2hours both sides.
If shops don't want to touch it....they don't know how to do it.