The rear drivers side exhaust manifold bolt on my 2004HD 6.0 broke off recently and I was wondering if anybody has had this problem, and how difficult was it to remove and replace. Thanks in advance for any info.

 

The bolt sheared clean off, eh? Dang, that sucks. If you can get the exhaust manifold off or loose enough to gain access to the stud thats stuck in the block, you might be able to get it loose with some vice-grips, though I doubt it. I would first try the vice-grips, but if that doesn't work, try finding a stud/bolt extractor tool at your local hardware store. Depending on how it sheared, you may be able to extract it without removing the manifold.

 

if there is enough of the bolt still protruding through the manifold or with it off try the vise grip idea. if not try what they call an easy out. im sure your local hardware store will have this. good luck

 

and if usin an easy out, make sure you drill exactly center and dont go off course, i snapped the crank pulley bolt off once and use and easy out and it worked for me, use lots of penetrating lube too

 

I have seen this many times on the 6.0. The way I fix them is to completely remove the manifold. Weld a nut to the remaining portion of the bolt. Then you must use a torch to heat the area up around the bolt in order to turn it out.

 

Excellent ideas. I've heard the same responses from friends who have had bolts broken and needed to get them out. I'm now wondering why the bolt cap broke. Is this a somewhat common occurence for this engine and or body style? If so then I suppose it should become a maintence item, and be checked regularly? Thanks again for the great info.

 

I had the same issue and could not get the bolt out and found out a about a bracket that simply bolted on and repaired the problem. the part was called the "Origional KAP" the website is Kral Auto Parts LLC 507-354-1945 New Ulm, MN - Home i hope this helps

 

I do a set of these once a month. the only method that works is the nut welding method. It even works if the stud is recessed in the block. drilling is a time waster and potential way to wreck the cyl head.