Yeah I knew it, Sleeve Nuts for Exhaust Manifold Snapped, 440

[rakort]

Well as I feared, suspected, researched how to prevent, and everything else possible including days of soaking in penetrating oil, tapping with a hammer to help loosen and let the oil soak in, both of the long sleeve nuts on the passenger side exhaust manifold snapped off near the nut head.

I'm thinking I know what needs to be done to get through this and at least there is a long sleeve/tube remaining to help guide the drill as I drill out the remains of the nut and stud, but wondering if anyone has any tips to help me through this. I know this is a rhetorical question, but the exhaust manifold studs are hardened correct?

thanks
Brian

 

[khryslerkid]

If they're not hardened, thru numerous heat cycles they might be harder than a non hardened stud.

You have the right idea on drilling them out. Use a high carbon drill bit. Pilot hole first then step up a size at a time. Remember the manifold is shouldered for the sleeve. Don't drill that diameter any deeper then the dept of the sleeve.
Good luck. I need to do this on a 361 that I have.

 

[rakort]

Remember the manifold is shouldered for the sleeve. Don't drill that diameter any deeper then the dept of the sleeve.
Good luck. I need to do this on a 361 that I have.

Good thing I have a spare manifold I can measure the depth of the counter bore to the shoulder. Regardless, I do know its there and that is a point of concern.

I was considering taking the head off and doing this on the drill press, but guess there are a few head bolts I won't be able to get out with the manifold in place. Maybe I'll have to take the whole engine and mount it on a BIG drill press at work, LOL!

I'm puzzled why I could not find a similar discussion on here about broken sleeve nuts. Maybe I am just unlucky and these sort of thing happens to no one!?

:cussing:

 

[khryslerkid]

I went through the same delima. Hex on one of the threaded sleeves twisted off. You can't get to the head bolts with the manifold there.
I bought a good set of easy-outs. Found the right size that fit into the sleeve. Applied torque to it and cracked the sleeve!
I'm replacing the 361 with a 440 so I'll wait to deal with it after I pull it from the car...

 

[MOPOWER871]

I JUST WENT THROUGH THIS FEASCO LAST NIGHT, DRIVERS SIDE MANIFOLD SPIT OUT THE A CHUNK OF GASKET ON THE LAST PORT OF MY 440. NOTHING MORE ENOYING THAN A LEAKING EXHAUST MANIFOLD . SNAPPED ONE STUD FLUSH ON THE HEAD.EVEN THOUGH I SOAKED IT OVER NIGHT IT STILL BROKE YOU COULD HOLD A STEEL NUT SAY A 5/8" OVER THE BROKEN STUD AND USE A MIG WELDER TO WELD THE NUT TO THE BROKEN STUD. IF IT TAKES ,WHEN ITS COOL IT SHOULD COME OUT . ITS LIKE YOUR WELDING A HEAD ON TO A BOLT . BUT MY BOTTLE WAS OUT OF GAS .
SO I CENTER PUNCHED IT . USED A CENTER DRILL TO GET STARTED THEN TRIED THE CORRECT SIZE EASY OUT. THE PROBLEM WITH AN EASY OUT'S IS ITS PUTTING RADIAL TENSION ON THE BROKEN STUD YOUR TRYING TO REMOVE :violent1:.
FELT LIKE THE EASY OUT WAS GOING TO SNAP SO PLAN B- DRILLED OUT THE REMAINING MATERIAL ONE SIZE UNDER THE CORRECT DRILL TO TAP A 3/8-16" HOLE THEN USED A 4 FLUTE BOTTOMING TAP WITH LOTS OF SMOUT'S (PENETRATING OIL) AND SLOWLY TAPPED THE TAP AS I TURNED TO GET IT STARTED AND BASICALLY CUT OUT WHAT WAS LEFT OF THE BROKEN STUD'S THREAD'S. THIS WORKED GREAT THINK IT JUST PUSHED THE REMAINING MATERIAL INTO THE WATER JACKET OF THE HEAD WERE IT WILL SIT TRAPPED FOR ETERNITY .NO BIG DEAL . GOOD LUCK