OT manifold bolt

reomack

Member
2002 Ford Explorer heater tube leak, tube runs under the intake manifold so must remove the manifold to replace. So far I have broken two manifold bolts, gotten all but one of the rest loosened. The remaining bolt was so rusted that the 10mm 6 pt just spun on it. I have tried the bolt grip solution with no luck. I can't use heat on a plastic manifold.The bolt is nearly impossible to reach with a die grinder and a vice grip attempt ended in abject failure. I am out of ideas and patience. Anyone have any ideas?
 
is it the last fastener holding the intake assy on?

if you could drill the head would you have clearance to remove the intake?

if so, then you could slip a nut onto it and weld it on, protecting the intake surface. then it may come out.

you can also try a good square hit to the head with a hammer. if it was loosened any you can do this now. if it is still tight, might not be good for the assy. if you do cut the head off you can then hit it with a hammer.


do you have any of those sockets with the round lobes in them that work on head flats not corners? those could work.

Hobo is a pro mechanic.. hopefully he will be along and offer advice, tips, and ideas.
 
Well, I have taken the safety guard off my air powered cut off and I'm in the process of slowly and as carefully as possible grinding the head off the bolt. When it is ground off completely I will (should) be able to get the manifold off and then address the issue of the two broken and one ground off bolts. I will report back with results, positive I hope.
 
Well now, partial success! The manifold is free of fasteners and will be out shortly. Now to deal with the broken bolts! Thanks for the help and moral support.
 
OK. The manifold is out, the bolt with the ground off head is out and the two broken bolts are drilled. I very gingerly tried an easy out on one of them with no success. I have soaked them with PB Blaster and will wait til later to try again. Mission creep, I broke the egr tube getting the manifold out - groan. I have also found two injectors with severe corrosion damage so I am going to replace all 8. The truck has close to 230K on it so they probably don't owe me anything anyway.
 

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