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  1. #1
    Petty Officer 2nd Class
    Join Date
    Nov 2004
    Posts
    112

    Default exhaust manifold bolts rusted-how to remove?

    went to remove my manifolds on a 5.7 merc and was able to remove the 2 end bolts but the 2 center ones were rusted and just flaked off rust. cant seem to get a grip w/ a socket. how to remove without pulling engine?

  2. #2
    Supreme Mariner
    Join Date
    Sep 2003
    Location
    Kitty Hawk NC
    Posts
    20,072

    Default Re: exhaust manifold bolts rusted-how to remove?

    wow the choices here are many. use a dremel tool and reshape the flats. use an air chiesel and cut off the offending lumps of rust. use an oxy/acetylyne rig and burn them off(my personnal favorite) or a sawzall (reciprocating saw) with a good carbide blade and cut the manifold runner near the head. ya only have to cut the runner enough to slice the bolt. I have had a few shamrocks with ford motors that I just used and air chiesel and took the manifold apart in pieces. all depends on access.
    no tech questions by PM, they wont get answered.
    you have to be trusted by the people that you lie to .

  3. #3
    Petty Officer 3rd Class
    Join Date
    Dec 2002
    Location
    Charlestown, Rhode Island, USA
    Posts
    89

    Default Re: exhaust manifold bolts rusted-how to remove?

    Sears makes a nice set of damaged-bolt remover sockets. I've used them on several badly rusted bolts on my boat trailer and they worked great. They also make an impact gun set, although I wouldn't use a gun on manifold bolts (if you snap a bolt, you're screwed). Here's the link to the regular-grade set http://www.sears.com/sr/javasr/produ...id=00952166000 .Good Luck.

  4. #4
    Petty Officer 1st Class
    Join Date
    Aug 2004
    Location
    Wildwood, NJ
    Posts
    236

    Default Re: exhaust manifold bolts rusted-how to remove?

    Those bolts are pretty long, I'd try to chisel/break the heads off, an get the manifold out of the way, they I'd use PB Blaster and vice grips to get the remaining bolt out. I'd use heat as a last resort. A torch in the bilge is a scary thing. Once the manifold is gone, they'll eb easier to work with. This stuff takes just takes patience.

  5. #5
    Cadet
    Join Date
    May 2005
    Location
    atlanta ga
    Posts
    29

    Default Re: exhaust manifold bolts rusted-how to remove?

    you can use a 4 1\2 angle grinder with a flapper wheel to remove the head of the bolt.

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