As stated in previous posts, I'm about to install LPP LT's I purchased. But I am having quite a BIG problem with the old exhaust and need some advice. The connection to the Y-pipe and the back end ofthe exhaust was successfully but very difficultly removed after applying some PB Blaster.

All the bolts connecting the Y pipe to both manifolds don't want to budge. I soaked them in PB blaster and will wait till tomorrow and try again. This is not a HUGE concern as worse comes to worse, I can simple cut the Y pipe apart. Although i"d like to keep it. Or is it worth it, has 120 000miles on it.

But the BIG concern are my manifolds. The whole reason I decided to go with headers was because two bolts on each manifolds popped off. Only the heads, leaving a stem. So I sprayed the remaining bolts in PB blaster for 2 days, applying twice a day. Now I tried removing the remaining bolts. Only 3 of them came lose but with difficultly, the rest all stripped, some stripping after applying only the slightest pressure. So I grabbed a gator socket for the stripped bolts, one more came lose. But the second stripped bolt i tried snapped and no stem remains, So it snapped and is now lodged in the head without a stem.
At this point, I'm taking a break for advice.

so...I have 4 snapped bolts with stems, 4 that will come out, 1 snapped bolt with no stem sticking out of the head, and the rest of the bolts have stripped heads. Other than the 4 loose ones, all the bolts are weak and REALLY stuck in there, even after applying a very generous amount of PB Blaster.

What should I do at this point?

 

You gotta get a really good extractor kit. And PRAY!

Dustin

 

I have a decent kit, but the prob is even if I catch the broken bolts, even if i use my 120 volt hammer drill, it still wouldn't have the power to extract the stems. The bolts that came lose required most of my strength... and I'm not a weak little boy... I've been hitting the gym for years. These bolts will not come lose with the power of a drill.

I've never had to deal with such flimsy bolts for manifolds before. This is my fourth time doing this to a vehicle and never had such problems.

So... why do i have the feeling someone's going to say how fucked i am?

 

Last time i heard of that the guy bought a new motor...

Dustin

 

I have never ran into the problem, but don't take this the wrong way. Are you using the right size wrench to take them out.. I have never had mine round off.. Also for future ref try to have the motor warm enough where it is bearable to get them out.. Aluminum and steel don't like each other, the heat helps.. Usually if bolts are tight, if you hit them with a punch, hammer on the head it will shock them and 90% of the time they will come out.. For the bolts on the Y, get a torch and heat the **** out of them. Im with Dustin on the extracter kit.. GOOD LUCK. Try to find a right angle drill, a left handed bit, or if there is enough meat sticking out, try to weld a nut on the broken stud... If that don't work you might be ***'d

 

worst comes to worst just drill out the stud and helicoil it back to proper bolt size... i hear helicoil is stronger then the original threads....... kind alike welds

 

worst comes to worse time for a head swap...

 

Damn... guess I am fucked... I just tried hitting one of the remaining bolts with the hammer and the damn thing almost crumpled off, there's hardly a head left to it. At this point, even if applied heat, the friggin bolts are just too weak to even turn. I fear most of your answers may be right... Head swap or engine swap. And I'm totally fucked because I have this damn truck parked in my condo's underground parking, have no garage.

maaaan this blows.

I believe I know why I'm having such problems though. The truck remained in a good shape from undercoating all the time, but the manifolds remain over open ground, being hit with salt for it's whole life when being driven on the wet wintery roads I live on. This obviously corroded them and ruined the bolts. I'm surprise the rest of the truck is in a good shape.

 

welcome to my world lol. I had to do a head swap. BUT, that was because it was the back bolt on the driver's side, couldn't get anything to it. In your situation, if you can get to them, just drill them out.

 

Hmm... I'm trying to weigh my options here... If replacing the entire engine, I'll need to put the exhaust system back on (not hard) to pick it up since I only have this truck, find an engine lift and a place to do the swap. My first prob is finding a 5.3 liter engine, possibly a 6.0 (such as http://toronto.kijiji.ca/c-cars-vehi...AdIdZ119609989)

If I do a head replacement... first of all, with these trucks, is it possible to do this with the engine still in the truck? And does anyone know of a website offering heads at a good price?

thanks