3.0 Exhaust Manifold Bolt Broke Off....HELP! SOS - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 03-07-2010
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3.0 Exhaust Manifold Bolt Broke Off....HELP! SOS

The JBA headers for my 3.0 have been sitting on my workbench for 2 months and decided to install them yesterday evening. I had the weekend off and took my time. I unbolted the everything pre and post cats with no problems. I uninstalled the driverside exhaust manifold and installed the driverside with no problem.

THEN....I got to the passenger side....

I'm thinking wow tons of room to work over here, this should be easy, boy was I wrong. I start loosening all the bolts and proceed to the last top passenger's side exhaust manifold. SNAP....Now I panic. I quickly unbolt everything and get the exhaust manifold out. Bolt is broke below the surface....I drive all over town trying to find a close quarter drill with no such luck. I try my dremel and get a hole in the center but tore through 3 drill bits.

Also the Y-pipe doesn't line up at all on my 4wd.

Will an exhaust shop be able to blow out the broken stud on the manifold? I got everything bolted up but you can hear all the exhaust leaks. I can't redo the exhaust so I have to take it to a shop to have that fixed but I'm really concerned about the manifold driver's side bolt.




I'm kinda dissappointed with JBA and their headers being so far off from the factory Y-pipe.

Any advice....besides being bummed out.
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Old 03-07-2010
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Wow that sucks. I snapped an exhaust stud too but there was still enough sticking out to weld a nut to.
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Old 03-08-2010
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I went to the exhaust shop today and got an estimate to fix the y-pipe. The guy I always work with over there acted like it wasn't that big of a deal to not have that last top bolt on and wouldn't recommend removing the head to drill it out. He did however recommend a guy over at Ford who does it for all the F-150s and Mustangs. I went over to Ford and asked him about it and he said it would be around 4.5-5 hours ($87/Hr) to remove everything A/C related and reinstall everything.

I haven't ever messed with and A/C system before and was wondering how hard it was to remove all those components. Or should I let them have at it? Heck if I could remove all that stuff I could easily drill that bolt out.
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Old 03-08-2010
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any general mechanic should be able to remove the bolt as in the Y-pipe deal thats a very common issue with the aftermarket heads. some people just bent it a bit and use the rtv exhaust gasket
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Old 03-08-2010
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Quote:
Originally Posted by Silver View Post
any general mechanic should be able to remove the bolt as in the Y-pipe deal thats a very common issue with the aftermarket heads. some people just bent it a bit and use the rtv exhaust gasket
So you don't think I should take it to Ford?
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Old 03-08-2010
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The guys right about the bolt. Mine rusted and broke off and it doesn't leak.
Check home depot for the drill, I've seen it for about $100, or harbor freight, i bought on for $30 saturday.
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Old 03-08-2010
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drill that hole and retap it yourself its not that hard i did it on a motor home with a 350 in it
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Old 03-08-2010
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Quote:
Originally Posted by Downey View Post
drill that hole and retap it yourself its not that hard i did it on a motor home with a 350 in it
I don't have a problem drilling the hole and retapping it. I can't get any drill in there to get it out. It's up against the firewall and the AC box housing. Got any suggestions?
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Old 03-09-2010
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So you don't think I should take it to Ford?
i would not take it to a stealer ship but and trust worthy shop should be able to help get the bolt out.
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Old 03-09-2010
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i broke one last week i left it i put the mainifold back on and bolted it up and no leak
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Old 03-09-2010
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yeah my top and last one on my passenger side broke too but it doesnt leak so i dont worry about it
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Old 03-11-2010
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I have the same problem, it broke off naturely and it leaks but not worth it to have someone do it or me to pull the entire head to get to it.

If you find somewhere to get a drill small enough to get to it let me know.
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Old 03-11-2010
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Right angle drill maybe?
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Old 03-11-2010
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Quote:
Originally Posted by Robin Hood View Post
Right angle drill maybe?
It's still too big. Anybody know what that black shroud against the firewall on the passenger side is hiding behind it?

Quote:
Originally Posted by muddin'Ranger View Post
I have the same problem, it broke off naturely and it leaks but not worth it to have someone do it or me to pull the entire head to get to it.

If you find somewhere to get a drill small enough to get to it let me know.
I wonder if we could drill through the backside if we take off the vavle cover. I'm not sure if that bolt sits inbetween a set of valves or not.
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