i need some help and advise please... i just got my header and want to replace the manifold but from what ive heard and been told its a real nightmare to do(if a bolt breaks) so what can i do to avoid this problem ive already used 2 cans of p.b. blaster and been drowing it a couple times a day for a week or so is there anything else before or during the replacement i can do

 

take your time, go slow, but bolt breaking on these is very common

 

i would suggest to get the car up to opp temp and remove the manifold while it is warm. Bolts have a less chance of breaking that way.....put on some gloves of course....

 

Personally I find it hard to wrench in welding gloves lol lol Those manifolds get way hot real fast so if you go this way be carefull or you will get burned badly

 

welding gloves? no i mean mechanic gloves...i dont know about the original posters abilitys but i can remove my manifold bolts without touching the exh manifold.........

 

cool i was gonna try taking a torch to the bolts as i went and like i said ive been drowing em a couple times a day for a week , week n half now with pb balaster i guess theres really not much else that can b done to avoid this hu???

 

Then you have to pull the head.

Thats after you break off a hardened "EZ Out" bit in there.



Pay a mechanic to do it. If he breaks one off, its on him.

 

I pulled the manifold of a 98 TJ awhile back and it was pretty easy. PB blaster!

 

I found a DIY on eHow on how to replace exhaust manifold on a jeep cherokee. It might help you go through this repair of your exhaust manifold.

 

After that comes the wailing, gnashing of teeth, and rending of garmets.

 

Broken exhaust studs are common when removing manifolds. Tons of PB and patience are your friend, don't just try to crank out your fastener, use lots of PB and go back and forth (out, back a turn, repeat and so on), sometimes I get lucky, sometimes not.If I break one I don't even mess with ez outs or extractors anymore, your just going to end up tapping it anyway. May as well start there. may as well not have a broken ez out in the way.

 

the broken piece still needs to be removed.....

 

Thats what a drill bit is for

But yeah this sounds like a giant PITA. It depends how rusted yours are. Mine are ridiculously rusted. I think it would just crumble. One day I will get that taken care of

 

Sorry I should have said "drill and tap".

 

just out of curiosity what header did you get? and are you going to replace the crushed pipe just after the header?