2500HDKartRacer

iTrader: (1)

I'm installing Thorley Tri-Y headers on my 2005 2500HD 6.0L. The driver's side rear exhaust manifold bolt has been broken for awhile. It wasn't broken flush with the heads so I wasn't too worried about getting it out. I was working it out with vice grips when it snapped off flush with the heads. It had turned 2-3 turns before it snapped. I cannot drill it out since it is too close to the fire wall.

Will I do damage to the new headers by running them temporarily without that bolt? I don't have time right now to pull the heads to extract the snapped bolt properly. I plan on swapping cams so I'll probably pull the heads at the same time and maybe swap to 243 heads??

Let me know.

GMCtrk

iTrader: (27)

If wont damage anything but it will leak and it will throw your o2 sensor readings off resulting in a rich condition.

Isak81

Weld a nut to the stud and turn it out. If it is broken beneath the surface weld a tit up to reach the nut. In Canada this happens all the time with the extreme cold/heat cycles. It doesnt hurt the aluminum.

TX Tahoe Z71

iTrader: (28)

Same things with mine, caused a slight leak but the popping sound was really annoying. After a year and a half, I finally had a shop take it out; took a drill and HeliCoil. Wasn't enough showing to weld a nut on there.

Ferocity02

iTrader: (59)

I had that same broken bolt for 5+ years, it only leaked when cold. Someone told me that if you remove the inner fender you can get to it with a left handed drill bit, but I call bs.

I finally swapped heads and went with stainless studs and nuts, much safer IMO.

colekill

i had a bolt sheared of at the head when i replaced the stock mani for pacesetter LTs. lol it was just gone and i never touched it, ran it with out the bolt never had any issues or noises...

2500HDKartRacer

iTrader: (1)

I'm borrowing a 110v MIG welder from a friend. I'm going to attempt welding a nut to the broken stud.

Are there any precautions I need to take before welding? Do I need to disconnect the PCM to avoid the risk of toasting it?

I assume I should ground the welder to the engine at the alternator bracket.

2000chevysilverado

iTrader: (11)

Disconnect battery pcm will be fine ive welded on mine several times just unhook battery

brent1976

iTrader: (1)

Weld a little to the end of the bolt first, so you have something to weld the nut to. Plus the extra heat will help break it loose.

03sierraslt

iTrader: (22)

Yep, just unhook the battery and computer.