Remove a Broken Exhaust Manifold Bolt - EASY in 15 Minutes! No Disassembly!

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Published 2019-06-22
This is a tutorial on how to remove a broken off exhaust bolt in a cylinder head without taking it off the engine! You do need to take the exhaust manifold off though. The video applies to any engine regardless of cylinder count.


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*Disclaimer: Please use all safety precautions

All Comments (21)
  • @OMGWTFFYA
    Mate, using the torx was the best advice that worked a treat when my easy outs failed.....thanks mate you're a legend
  • Super video, got an old 44 year old motorcycle to restore...came with one manifold exhaust collar bolt snapped off 1/2 into manifold. Considering options. I was thinking about drilling out an 8mm bolt so it can go in remaining threads, and pr0vide guide for 1/8th inch bit, then use that hole with extractor, or the torque socket you suggest. It is very easy for a drill to drift when drilling out center of a snapped bolt for reasons you cover. Thanks for this advice.
  • @andrewball6460
    This worked for me on a rear manifold, up in a tight spot. This goes in the top 10 most awesome tricks I've learned for sure.
  • @rican6502
    This trick just saved my customer thousands of dollars. It was almost to easy. Thank you.
  • @IH8CA
    Thank you so much!!! This saved my butt on a 5.7 Hemi. Even with a special tool, couldn't get the right angle to drill clean. This worked perfectly, thanks!
  • Wow awesome tip huge thanks man! Only had 1 break on me luckily installing headers on my 2013 Charger RT going to try this tomorrow.
  • Wow lmao this is amazing. Your manifold videos are the best! I've been watching a few and you are straight to the point with GREAT tips! Thank you!
  • @BoringCooking
    also worked great for me. the torx bit really jams into the broken bolt. many many thank you for the tip.
  • @rokyle2323
    Dude I watched this video and thought it was dumb but HOLY SHIT ITS SO EASY seriously your the real MVP this was the best trick ever
  • One thing you need to watch for on the easy outs is that because of the way the spiral flutes draw the tool into the hole you can actually end up expanding the stud and jamming it even tighter. Been there, broke the easy out, got the t shirt
  • @michaeld5664
    just did it myself today and it worked beautifully!!
  • @user-mh3rq7zd1h
    Thank you! It just worked for me, to remove a broken stud on a 2012 GMC Terrain!
  • Thank you so much!!!! This one trick worked when everything else I tried failed (multiple times).
  • @watchfast1
    Size 2.5 hardened steel drill bit and T20 Torx bit. The punch is a narrow center punch. Use oil to dissipate the heat on the cutting edge of the drill bit. The right angle drill is 3/8”.
  • @sbfguy7793
    Just broke 7 drill bits on the broken bolt in my head for my intake manifold bolt. Luckily I got it, but now I have a broken exhaust bolt that I need to remove. Fun.
  • Thank-You for this video! My old 1998 ek hatch stripped the bolt on the exhaust manifold earlier on a snow storm.
  • I'm having trouble drilling into my broken exhaust bolt. I started with a 1/8 inch bit and I used cutting oil but it isn't going in very well. Could recommend a drill be that would definitely cut into that more easily?????
  • @NoahsArk4532
    Any idea what drill bits or what size? I should buy to drill out rusted/broken 2002 Honda Civic exhaust manifold bolts? Just wanna make sure I get the right kit or use the right size