How to Get Broken Bolts Out of Exhaust Manifold: A Comprehensive Guide

To get broken bolts out of an exhaust manifold, use a drill with a reverse function to remove the remaining portion of the bolt. When doing this, ensure that the drilling is only on the bolt itself in order to avoid damage to the manifold.

Removing broken bolts from an exhaust manifold can be a daunting task for many mechanics, but it is an essential skill to have as it can save time and money. A broken bolt in an exhaust manifold can lead to leaks and reduced performance of the vehicle’s exhaust system.

The easiest way to remove a broken bolt is to drill into the center of the bolt using a drill bit that is a similar size to the bolt, then use a wrench to remove it. It’s essential to take precautions to ensure that when drilling, only the broken bolt is drilled, and not the manifold itself.

In this article, we’ll examine the different ways of removing broken bolts and explore the tools and techniques required to get the job done right.

How to Get Broken Bolts Out of Exhaust Manifold: A Comprehensive Guide


Understanding Exhaust Manifold Bolts

When dealing with broken exhaust manifold bolts, it’s important to have an understanding of these bolts. Exhaust manifold bolts are crucial because they keep the exhaust system in place. At times, these bolts may break due to over-tightening or vibration.

It’s crucial to investigate why a bolt broke in the first place, as it could be due to an underlying issue. When it comes to removing a broken bolt, there are several methods including using a drill, an extractor tool, or welding.

However, before attempting to remove the bolt, it’s important to spray the area with penetrating oil and let it sit. By understanding the basics of exhaust manifold bolts and knowing how to remove a broken bolt, you can solve this problem effectively.

Tools & Materials You Will Need

To remove broken bolts from an exhaust manifold, you’ll need specific tools and materials. For tools, grab a set of bolt extractors, needle-nose pliers, a hammer, and a drill. Make sure to get the appropriate size for the bolt you’re removing.

As for materials, you’ll need penetrating oil, a wire brush, and a bolt punch. Penetrating oil will help loosen any rust or debris around the bolt, while a wire brush will help clean the area. The bolt punch is useful for removing any remaining bolt pieces and freeing up space for a new bolt.

With these tools and materials, you’ll be able to successfully remove any broken bolts from your exhaust manifold and get back on the road in no time.

How To Remove A Broken Bolt 6 DIFFERENT WAYS – LS Exhaust Manifold

How To Get Broken Bolts Out Of Exhaust Manifold

Getting broken bolts out of an exhaust manifold can be a challenge, but there are several methods that may work. Using a penetrating oil is often the first step, as it can help loosen the bolt. If that doesn’t work, heating the area with a torch can sometimes expand the metal enough to free the bolt.

If the bolt is completely stuck, drilling it out may be necessary. At that point, an easy out tool can be used to extract the remaining bolt. Another option is to use a bolt extractor socket to grip the bolt and turn it out.

Finally, welding a nut onto the broken bolt can create a new grip point to turn it out. Choose the method that is best suited to your situation and feel confident that with patience and persistence, you can get that broken bolt out of your exhaust manifold.

Precautions And Tips

When it comes to removing broken bolts from the exhaust manifold, taking precautions and following tips can make the process easier. Safety should be a top priority, so wear protective gear like gloves and eye protection. To prevent bolts from breaking, use lubricant during removal and apply heat if needed.

Avoid making common mistakes like using the wrong tool or applying too much force. Additionally, take breaks if you feel frustrated or overwhelmed. Remember to stay patient and careful throughout the process, and seek professional help if needed. By following these precautions and tips, you can successfully remove broken bolts and avoid further damage to your vehicle.


After reading this article, you should now have a clear idea of how to get broken bolts out of exhaust manifold. While it can be a challenging task, with the right tools and techniques, you can successfully remove broken bolts without causing further damage to the manifold.

Remember to use penetrating oil, a drill, and a high-quality bolt extractor to make the process easier. It’s also important to take your time and be patient, especially if you’re dealing with stubborn bolts. And if you’re unsure about the process or feel uncomfortable tackling it yourself, don’t hesitate to seek professional help.

With these tips and tricks, you’ll be able to get your exhaust manifold back to peak performance in no time. Happy fixing!