Box truck exhaust manifolds

[93redzj]

So I finally took possession of my box truck to use for work, it needs the exhaust manifold bolts replaced, I guess it’s common for them to break off? Drive side is already off, just needs reinstalled. Passenger side needs removal and removal of broken bolts, I seen at least two with a quick inspection. My buddy that I bought the truck from made me well aware that the passenger side was gonna be a PITA and there was a reason he hasn’t done it yet, so naturally I said challenge accepted…..but before I beat my head against the wall too much, any tips or tricks to removing these broken head bolts? It’s a ford V10

 

[Croatan_Kid]

If they're sticking out: weld a nut on them and let cool. They'll probably back right out.

If they're broken off flush: weld a nut to them and let it cool. They'll probably back right out.

If they're broken off down in the hole: left hand drill bit. Sometimes they'll spin right on out. If not, tap a square easy out in it and carry on. I generally drill all the way through the broken off piece if I can. It lets it relax a little.

 

[93redzj]

If they're sticking out: weld a nut on them and let cool. They'll probably back right out.

If they're broken off flush: weld a nut to them and let it cool. They'll probably back right out.

If they're broken off down in the hole: left hand drill bit. Sometimes they'll spin right on out. If not, tap a square easy out in it and carry on. I generally drill all the way through the broken off piece if I can. It lets it relax a little.

Thanks! My next concern is going to be gaining access to them. Without pulling the engine. I haven’t looked into it thoroughly yet. Was going to do that this weekend and really gameplan as to how I’ll tackle the job. But initially, it’s stupid tight right there, looks like maybe the fender well lining can be taken out, or I’m even open to taking the fender off altogether in order to gain easy access. So I’ll see about that this weekend and keep those methods in mind

 

[Noel]

Thanks! My next concern is going to be gaining access to them. Without pulling the engine. I haven’t looked into it thoroughly yet. Was going to do that this weekend and really gameplan as to how I’ll tackle the job. But initially, it’s stupid tight right there, looks like maybe the fender well lining can be taken out, or I’m even open to taking the fender off altogether in order to gain easy access. So I’ll see about that this weekend and keep those methods in mind

I’ve done many of these. Get to the ones you can, taking the fender off will do no good. These do come out much easier than the Ls ones for some reason. But will be a couple in the 6.8 you can’t really get to easily. I have had to leave a couple in that I couldn’t get to but with a new gasket it sealed up 99%

 

[93redzj]

I’ve done many of these. Get to the ones you can, taking the fender off will do no good. These do come out much easier than the Ls ones for some reason. But will be a couple in the 6.8 you can’t really get to easily. I have had to leave a couple in that I couldn’t get to but with a new gasket it sealed up 99%

Well that’s good to hear

 

[Monkeynono]

I had a jig kit I used at work for the Fords. Made drilling easier.

Also from my experience (I did a fuck ton of these) I settled on using the biggest impact gun I could on the bolt that hadn't broken yet and had good luck getting them off without out breaking.

 

[Croatan_Kid]

Is this a truck, cabover, or van based box rig?

 

[93redzj]

Is this a truck, cabover, or van based box rig?

It’s a former U-Haul truck

 

[Croatan_Kid]

Ahh, ok. Yeah, accessibility might suck.

 

[ghost]

Sounds like a good candidate for a Godzilla swap! (You know I had to!) GL!

 

[93redzj]

Just a little update with what I’m working with. Shocks are shot haha but new ones were included. Gonna need brakes as those rotors are as groovy as the 70’s and then there’s the exhaust. Driver side was already off, I’ve got two bolts still in block and two others are broken off in the block. Meanwhile on passenger side, I believe there was about 4-5 that were broken off already. Haven’t attempted to remove anything on that side yet