Darn Exhaust Manifold Bolts

[arrowshooter]

My son has been nursing his Ram 1500 along with broke exhaust manifold bolts for a while now and it started running bad enough that it was time for the plunge. Had three bolts broke flush and I was able to get enough metal built up to grab with the vice grips. Really easier than I expected. Tried welding a nut on first, but that was no bueno. I've used that little Harbor Freight welder quite a few times now and works like a charm.

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[Capn Jack]

I was reading an article on those welders and they sure are tempting.

I have an old 20 amp/ 110 AC Buzz box, but my garage circuits don't have enough poop to use it.

 

[arrowshooter]

I have had three flux wire welders from HF and this one is be far the smoothest and way more quiet.

 

[Alexx1401]

I have had three flux wire welders from HF and this one is be far the smoothest and way more quiet.

I too have come real close to buying one from them. Would VERY seldom use it but, when needed damn things would be great to have.

 

[hongkong2]

On sale now for $149 https://www.harborfreight.com/easy-flux-125-amp-welder-57861.html

 

[40nascar]

The boy better get that exhaust port sealed up good before he starts burning valves/seats.

 

[Caveman Jim]

I wouldn't know where to start with one of these welders because all I weld is wood.

I been hearing a lot about this problem, what the heck is causing it, no-quality bolts?

 

[gmerkt]

I too have come real close to buying one from them. Would VERY seldom use it but, when needed damn things would be great to have.

I think that pretty much describes the utility of Harbor Freight stuff. Some of if is good for general use. But I think another some of it is good enough for occasional use. On that basis it pays for itself. I've got a few HF automotive tools that I use very seldom but when heeded are awfully handy. I don't know if pros working at the Ford store would laugh them out of their shop, but good enough for me on those rare occasions when I need them.

 

[gmerkt]

On vehicles that I'm familiar with, I've never had exhaust manifold bolts routinely break off in the cylinder head like that. When I used to work on old Lincolns, the issue was frozen up nuts on ex.man. studs where the exhaust pipe flange fits on. On lots of those, the stud would turn out of the man. before the nut would turn loose. If the stud broke off in the manifold, it was a real problem.

 

[ron]

The old 460 V8 Ford truck motors had problems with breaking exhaust manifold bolts on the right side rear.
I broke several and replaced the exhaust manifolds twice. When looking for exhaust manifolds in the junk yard
they had the same broken exhaust manifold bolt! I think using some anti-seize on the bolt threads would
help.

 

[Stomper]

The old 460 V8 Ford truck motors had problems with breaking exhaust manifold bolts on the right side rear.
I broke several and replaced the exhaust manifolds twice. When looking for exhaust manifolds in the junk yard
they had the same broken exhaust manifold bolt! I think using some anti-seize on the bolt threads would
help.

Good to know, my brand new (employer supplied) custom E-Series cabbed work rig (it's more like a rolling work shop that's 10.5' high with the ladders on top) has a Ford 460 in it that gets 9.4-10.2 miles to the gallon!

 

[Alexx1401]

I think that pretty much describes the utility of Harbor Freight stuff. Some of if is good for general use. But I think another some of it is good enough for occasional use. On that basis it pays for itself. I've got a few HF automotive tools that I use very seldom but when heeded are awfully handy. I don't know if pros working at the Ford store would laugh them out of their shop, but good enough for me on those rare occasions when I need them.

YEP! I have been shopping at HF since before the net came along. First stumbled on a catalog one day and ordered some stuff. Later they opened the first store here. I doubt any of their stuff would hold up to professional use but, for me? Stuff is great. Have a bench grinder and a power miter saw that I bought so damn long ago I have no clue how old they are. Every time I need them they still just work. Late last year bought an 80 volt battery mower from them a member here said were great. It impressed hell out of me. Grass was wet and over tall. Damn thing cut it every bit as well as the gas one I had which I donated to the crew here. So this spring added a hedge clipper and string trimmer that use the same batteries. They are just as powerful as the Echo gas stuff the crew here uses and no noise and gas to mess with. This is why I may well buy one of the welders they sell. I would seldom use it but, damn thing would sure as hell be handy to have when I did need it and at a price that makes them real tempting.

 

[dogface2000]

I've had that same welder for several years now. Used it for many hours. Welds fine. Cuts deep enough for anything I've needed, some of which held up to heavy force. I think it's a good tool.

 

[bionic knees]

Good to know, my brand new (employer supplied) custom E-Series cabbed work rig (it's more like a rolling work shop that's 10.5' high with the ladders on top) has a Ford 460 in it that gets 9.4-10.2 miles to the gallon!

The 460 Fords have interference threads on the factory exhaust manifold bolts, making them a real pain to get out. been there, done that a bunch of times. nearly 20 years as a Ford tech

 

[arrowshooter]

I been hearing a lot about this problem, what the heck is causing it, no-quality bolts?

Aluminum head vs Iron manifold. The two heat and cool at different rates which is what shears the bolts.

 

[Caveman Jim]

Aluminum head vs Iron manifold. The two heat and cool at different rates which is what shears the bolts.

I'd be ditching those cast iron exhaust manifolds and putting on a pair of headers…

 

[bionic knees]

Aluminum head vs Iron manifold. The two heat and cool at different rates which is what shears the bolts.

Not just aluminum and cast, cast on cast has been doing it for years.

 

[Hemlock]

I had this problem on a "06 1500. The problem is Dodge was making everything cheap and that included thinning the material the manifolds were made of. Heating and cooling warped the manifolds and leaks were the results. Warping was compound that by the wrong grade of bolts and everything starts eating away. An exhaust tick is a sign that the problem is starting. I thought it was a lifter that wasn't pumping up when cold because it would go away after the engine warmed up.
Costly but new aftermarket manifolds and a proper grade of bolts cured the problems. An even better cure was I got rid of the truck. Of course, after it broke a valve spring (common for those years) and blew a rod out of the pan, and I had a Jasper engine installed. Never again a Dodge product for me.

 

[Jmorris]

Aluminum heads, cast iron manifolds and heat cycles, seem to make it pretty common. Happens with Chevy and Dodge more than Ford, Coyote at least, as they use larger diameter fasteners. The good news is they are dissimilar metals so there is not much worry of welding the broken fastener to the parent, the heat also helps break any bond, although they are generally not very tight anyway, now that the tension is gone.

With a TIG you can remove very small things too.