broken exhaust manifold bolt - JeepForum.com
 
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post #1 of 11 Old 03-21-2001, 03:02 AM Thread Starter
jeepnmad198
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broken exhaust manifold bolt

I have a 95 yj with a 4 cyl, on a recent inspection the tec discoverd the first manifold bolt was shared off. It failed inspection. He said that was not the first time he had seen that on a JEEP. Any one run into this problem? whats the best fix?


1995 YJ (0lll0) Spring over, 33" Swampers.
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post #2 of 11 Old 03-21-2001, 11:09 AM
JR
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I am not sure on how to fix it. But does it make some damn weird noises?
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post #3 of 11 Old 03-23-2001, 12:47 PM
jmsjeep
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Did it fail because of visually seeing the bolt or fail because of emissions.

If it was visual Just J.B, weld a bolt head in place. (who would know) The rest of the bolts will hold the manifold tight enough.

If its letting exhaust out there then its not tight and should hear it, you should also see carbon around it. Could you use a bolt extractor?
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post #4 of 11 Old 03-23-2001, 02:44 PM Thread Starter
jeepnmad198
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J.B. weld what a great idea, although you can see carbon around it. I could use a bolt extractor but it is in such an akward place I would have to remove all the power steering pullys and the airfilter housing, just to get the drill in there. I never had much luck with bolt extractors, I usually just make it worse. either way somthing needs to be done..

1995 YJ (0lll0) Spring over, 33" Swampers.
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post #5 of 11 Old 03-26-2001, 02:37 PM
grignac79
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I had an 86 that was always shearing off the mainfold bolt closest to the firewall. I had to drill it out and finally got the sides thin enough to pry the remains out. I then had to clean out the threads.

A suggestion: I filed the mainifold bolt holes out with a round file and made the holes oval on the front and back holes in the horizontal direction to allow the mainfold to move. Cylinders 1 and 4 seem to be the worst. I also put an antisieze on the bolt threads. I still ended up retorqing the bolts frequently. I also used a gasket when I put it back in. The problem with that is I had to replace it every two years due to the manifold wearing through it due to the movment.
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post #6 of 11 Old 10-04-2010, 05:54 PM
TexasYJ
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1995 YJ Wrangler 
 
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Recently replaced my cracked manifold and had a bolt broken off flush with the head. I soaked it over a couple of days with PB blaster. I then drove it to my buddies house, I am currently in an apartment, to do the deed. Pulled the manifold and related pieces parts, soaked the broken bolt one more time and broke out the drill. Started with a pilot hole. When I started to drill with a bit a couple of sizes larger, the bolt end turned. Removed the bit tapped in an easy-out and out it came. Replaced all the bolts with grade 8 and new torque washers.

Edit: Sorry for got to include it was a 2.5.
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post #7 of 11 Old 10-04-2010, 06:51 PM
kloppk
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This is a fairly common problen with the 2.5 engine.
The front and rear studs exhaust manifold studs are prone to snapping off.
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post #8 of 11 Old 10-04-2010, 07:21 PM
vicker
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defntly go with a grade 8 bolt. i highly dought a bolt that hard will ever brake off. the shearing strength of a 1/2" grade 8 bolt is typically around 90,000lbs depending on its compisition. I think there 1/2" bolts rite.
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post #9 of 11 Old 10-04-2010, 09:03 PM
mweber01
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If its broken off flush with the manifold, maybe the easiest thing to do would be start taking things off, including the exhaust manifold, and hope that you get lucky and have a little bit sticking out of the head. Had this happen to me with a thermostat housing bolt. Had about 1/4" sticking out of the head, pulled the head off to replace the head gasket anyways and clamped a pair of vice grips on that SOB and twisted it right out. Might be worth a try so your not banging ur head on the hood and getting frustrated...
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post #10 of 11 Old 10-05-2010, 04:50 AM
Kick
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erase

95 yj 4 lungs 3.5 bds more shackles ox locked 32" BFG AT KO patriot 9500 sye
08 unlimited rubicon 1"3/4 daystar lift
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post #11 of 11 Old 10-05-2010, 04:50 AM
Kick
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My front and rear are both snapped off(100,000 miles ago), just make sure the others are tight and don't worry about it. jb weld a fake head if needed. In the future I'll put a stainless header with new stainless bolts when necessary. Also make sure all your exhaust hangers are in good shape.

95 yj 4 lungs 3.5 bds more shackles ox locked 32" BFG AT KO patriot 9500 sye
08 unlimited rubicon 1"3/4 daystar lift
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