In this video I show you how to remove 4 broken exhaust manifold bolts in this 2010 Ram with a 5.7 hemi with out a drill. Wanna see the manifold installation? Here is the link to that : • Installing Exhaust Man...
Great video, as the original owner of an 09 Ram 1500 Hemi, I have lifetime powertrain warranty. My exhaust bolts have been replaced FOUR times, about every 40K miles. I have 202K now, past due, 50K on this set.......
Tip on welding nuts to broken bolt/studs, especially when the bolt is broken below the surface; weld build-up a nubbin on the bolt BEFORE putting the nut in place for welding. This does two things: it lets you more precisely place the initial weld metal on the bolt, then it lets you easily position the nut over the nubbin for final welding. I've been using this method for many decades and it almost always works for me. Love your videos.
I know how to weld and I'm a mechanic that's still my question... can you just attach the negative probe on the head or block and send the current through the motor... wouldn't that risk sensors being zapped
I'm watching this because I have to do this this weekend... Got a major exhaust leak cause a bolt broke off. Gotta take exhaust off and remove them stuck and broke bolts. I hope it's as easy for me as you make it look
I love the style of Eric O. in these older videos. He seems to be more patient, more expletive in his description of the problem & awesome camera angles. Also one of the only video content creators to show this method of broken stud removal. So much more reliable and non-damaging compared to drilling. Great job
When I first saw this, I was blown away. Eric has a tremendous amount of natural ability plus a whole lot of learned skills. Have watched all the vids. Love the channel!!!!
Bill Rimmer He,s the closest thing to my brother Dan who has 40 yrs managing Kawasaki, Suzuki, Honda, Yamaha, and is a walking genius. so Eric your in good company.
Bill Rimmer It truly is a natural God given gift he possesses. Some guys have it some don’t. I’m the same way but my trade is in commercial maintenance. I can literally look at something and in my head picture how it works, should come apart, and go back together. Same way with my cars. I can’t teach it to anyone it’s a gift. My Son has it too but he channels his to computers and programming. He makes more money and never gets dirty!!!!
I just want to say thank you and i really appreciate for you to take your time to film step by step of what you are doing. It is extremely resourceful.
@@theminion2771 Small bolt and the constant hot/cold cycles mixed in with vibration is what I believe is happening. I need to get this job done on my 09 5.3 Silverado .
Eric you've done it again. You have just given me the answer to one of my greatest fears when it come to working on the exhaust system; broken exhaust manifold bolts. Thanks again Eric. I watch your videos all the time. You make it all seem easy. Thanks for explaining everything as well as you do.
Inspiring for those of us with the Hemi manifold tick! My '04 2500 has 328,000 Miles on it and wont pass inspection with Mil lite on. "Lean on bank one." Was just going to hire this out, but you made it look so painless and easy! The Trademark of a PRO!! Thanks for the great video and camera work! Well done!
That was an amazing video! The moment I heard you say that the bolts were broken I figured you'd drill them out. I was looking forward to seeing that process but was really surprised with your ingenuity for welding nuts onto the bolts to extract them. That is a perfect example of someone that truly knows their craft. Thank you!
Just changed my manifold in my 2009 Ram. Had one broken bolt and i tried to remove with easy out. Of course it snapped off. Thankfully I had watched this vid previously and learned your technique of welding on a nut. Worked like a dream!! Thanks for everything you teach us, love the channel!
In no way am I a mechanic and I was skeptical of this working. Figured I would go for it anyway, borrowed a freinds welder and it worked for me. Who knows just how much it saved me but I really appreciate the video and the incredible knowledge. Thank you very much.
I had to replace my gaskets and had two broken studs on both sides. Luckily I had purchased a mig welder a few months ago and your method of extracting the bolts worked perfectly. Thanks for the video......it saved me a lot of money and time. Replaced both sides in about three hours!
I appreciate how you maintained your cool head working through this hateful job, and I will look back to your calm approach the next time I am presented with this job.
you're the man, Eric! Get the job done, show the viewers how it's done, and No swearing or foul language in the process! you deserve an award. PS: if i was a mechanic, i would post a big sign on my shop saying, "WE DO NOT FIX DODGE PRODUCTS"!
Very nice work. Always great to see a professional working his trade and always a good feeling when those broken or seized bolts start backing out of the hole. Just used this method to remove 5 broken cylinder head bolts on a 1959 outboard motor I'm rebuilding.
Extremely talented and patient mechanic. In those tight areas making it work like butter like that. Hats off to you SMA, seriously! Now if only their was a million more of you on this planet we’d be in a much better place.
Good video, I was able to extract my broken exhaust stud front drivers side 2013 Dodge Ram 1500 5.7L Hemi with your technique. Took me a little longer then I thought, took like ten nuts before I got a good weld. Thanks for your video it helped.
I Have a 2008 F-250 5.4LT with and exhaust manifold nightmare. The studs are and nuts have turned into blobs of rust. I wanted to try this method and you have proven it is a viable path to follow. Thank you!!
two broken bolts in the head............huh................that's where I throw a bunch of stuff around the garage, curse a lot, and say "f'it...........I give up" Kuddos to all you REAL mechanics who sort this stuff out every day!!
installed 2 new manifolds on my son's 2008 ram 1500 5.7 over the weekend following your guidance and it was a breeze. 3 studs broken off in heads and mig welding nuts worked perfect. Also studs for head shields were in bad shape so i cut the heads of them with acetylene and removed with vise grips after removing manifolds. thanks for the video!
Thanks so much for making this video. I followed your instructions and welded the nut onto my broken bolt. Worked like a charm! With the help of this video I was able to do this repair myself and saved over $700 compared to taking it to the stealership. You did a great job explaining and showing all the steps. Thanks again!!!
Excellent video. Not only did I learn much for the next challenge that will eventually come, but just listening to your voice and personality I find very soothing and comforting. You really are gifted in many ways. Thanks for your production, and greetings from New Rochelle N.Y.
Really nice work man! Getting that 2nd bolt out was really some great work. In a case like this, brand new manifolds and bolts seem the smartest way to go. Also. Anyone owning one of these trucks should have these bolts checked out, loosened and replaced periodically. Getting that 4th bolt out was something only the really gifted mechanics pull off. Thanks for the tutorial.
Great video! This is one of those repairs that looks easy if you have a climate controlled garage, lift, and MIG welder. Car repair would be a breeze in these conditions! Meanwhile, I'm in Minnesota jacking my car up in a gravel drive way with only a butane torch........Time to pay the mechanic......
I had heard horror stories about replacing exhaust manifolds, and was a little apprehensive about replacing mine on my '03 Dakota 4x4 4.7L. Fortunately none of the bolt were already broken off, I just had cracked manifolds. I ended up taking my cutoff wheel and removing the heads of all the mounting bolts so that I could slide the old manifolds off, and still have enough material of the bolt to deal with getting them out of the heads. Of the 16 bolts I was able to remove all but one by hand. The last one I had to put a pair of vice grips on and turn it about a quarter turn then it came out by hand. I like the videos, you do great work. Keep up the great content. I believe that if people have the know how and ability to do things why should they pay other people to do what they can do for themselves.
I'll often watch these videos of yours regardless of topic, because they show skill. and always prove helpful down the road. Don't let your head swell, your hat is your trademark
Great work! That's a really satisfying feeling when that stud breaks loose and comes out. I've personally had better luck just building up a "blob" on the remains of the bolt and then grabbing it with a Craftsman bolt extractor. Placing a nut over it and squeezing the trigger was like shooting in the dark for me...ended up breaking the weld and wasting nuts haha Works great on rusted brake bleed nipples too...just grind it flush with the caliper and weld on a blob. After practicing this method, the drill is now the last resort!
Hey thanks for watching! Yeah I've used the "blob" method too lol. Yeah the drill is the last thing out any more, I have had really good success using this method for years now. Mountain bikes and motors sounds like me. I do enjoy hitting the trail and back roads, not sure if I wanna do it on a 1x10 though :) Enjoy the vids and ride on man!
I have removed bolts using many methods. I've also broken a lot of tools in the process. Welding a nut onto the broken bolt is an awesome idea. This was well worth the time to view.
Just wanted to express how much I appreciate this video. I did my hemi's manifolds today and did it with confidence because of your video. What a great trick! It worked perfectly! Thanks much Eric!
Top rear stud was broke off flush with head on passenger side. Used the nut and welder trick and it twisted right out with ease. Really like the video. It made my job go slick.
There needs to be a recall on this with the Dodge Rams because I just took mines in this week to get repaired....it's a design flaw with cheap parts smh
Heck yeah brother, I got a 05 ram hemi had to replace those manifolds without a lift, so I jacked up the truck put it on stands then jacked the motor up about two inches one side at a time. So far so good it’s been 5 years so it’s getting that time again lol
Hey Eric.I just used the welding the nut on method on 4 broken exhaust manifold studs on the passenger side on my 2004 Ford F-250 5.7 liter gas engine..It worked great.The last one was a bugger.It took 8 tries before it grabbed it.I had to build it out first and then weld the nut on it.I had to heat up the aluminum head area a lot with a Mapp gas torch for 10 minutes first.This is what seemed to make it let go.My welder is an older Solar 165 with 75/25 gas.Tried with shielding gas but it worked better with .030 flux cored wire.Got a very strong bond to the stud with this.I kept the electrode hand piece on positive polarity.Got very good penetration to stud.Just wanted to Thank You for saving me tons of time,money and aggravation. You have a great you tube channel.
I had the back 2 bolt heads broken off on my 04 ram. I didn't remove the manifold but I was still able to weld a nut on the rest of the stud and back them out to replace the bolts. Did that and the ticking stopped! Great video!!!
I know it’s been 5 years but you help me out a lot I’ve been looking at your Chanel for a lot of amazing repairs and didn’t think I would ever come across this repair save me a lot of time . Your the best 👍
Your technique is great for bolt extraction. Yes, I did have a couple take-aways. One, I need to step up my game and get 100-times better at welding. Two, I'll use my improved welding skills to give your technique a go. Thanks for taking your valuable time to make, elevate and share your video.
That's the absolute best way to get those out but on the Fords they are much harder to get to. I just wish I knew how to weld and not rely on others. Maybe I can stop by and show me a thing or two during my Fixing Fords Across America Tour this summer. I think your shop setup is interesting too I would like to see that also.
FordTechMakuloco I have welded many of these. even pulled 17 out of a hundred year old boiler.. try a nut one size bigger... on mig set the voltage a bit higher but leave the wire speed alone...dont be afraid- it wont weld to the head, even a cast iron head...
Thanks for the help. I had to purchase a welder to remove mine in the same exact locations yours broke off. Watching this video over multiple times gave me the courage to get it done.
I've been doing this on my truck and the wife's Durango for a long time. A tip to extend the amount of miles between broken exhaust screw extractions, take the manifolds over to the belt sander and make sure the gasket mating surface is flat. They never are, and require a little sanding to get them flat. Probably some residual stress from the casting process, but usually the rearmost port isn't flat with the rest.
I'm get'n ready to overhaul my 1996 Isuzu Rodeo V6 engine - has 463,000 miles- it still runs fairly decent but valve guide seals are leaking, has an oil leak at back of valve cover cam seal (can't get a wrench on bolts to remove cover)-also few oil leaks here an' there. This video will help me with figuring out how to deal with exhaust manifold bolts - the worst part of working on cars if you ask me - Anyways, I really like the Rodeo - learned a lot about OBD electronics stuff on her - she been a good ol' gal. Shopping around for another ride the prices sent me right back to engine rebuilding- there's just nuthin' like driving something you rebuilt yourself - thanks for making this video Eric....cheers!
With modern metallurgy, I don't understand why they have not come up with a better material for exhaust manifold bolts ! Some kind of stainless that is not brittle and has adequate strength. Or at least go up a couple of sizes on the bolt/studs.
So I came across this video because as you may guess, My 1500 developed the "hemi knock" found out it was the passenger side manifold. 2 broken studs, had no clue if I could get it fixed myself without trying to drill them or taking it to a garage. Tried 3 times to weld a nut on, each time they just broke off. Ended up just slowly building a wad of material and grabbing them with a pair of vice grips, long story short, they both came right out! Since then been enjoying your videos very informative and entertaining! Above all, probably saved me a bunch of money that someone would of done the same thing! Thank you!
Well done !! As a professional automotive machinist/ engine builder . 40 years in the trade its Nice to see a mechanic with the Skills to remove broken bolts From a head, especially in the vehicle. I very often have to bail Out failed attempts. Meaning i get To remove there broken off drill bits, easy outs, blown out holes Etc. Maybe i should do a video on That some day.lols
What an excellent demonstration, thanks for going through the effort of filming. I presume the extra heat needed to weld aluminum (rapid heat dissipation) is why you can weld so close to the head. Have you encountered any problems accidentally welding the bolt to the a steel head? Aside from removing the neg pole of the battery and avoiding fuel components, do you take any special precautions before welding on an engine?
No extra precautions taken other that the ones you mention and in reference to the cast heads I have hit the head while welding a bolt but it does not seem to bond to the cast well if that makes sense. The weld seems to break free from the cast really easy.
I've use that technique many times for busted bolt removal, I find that putting a little nugget of weld on the end of the bolt before welding the nut on works very well. It centers the nut and gives a nicer penetration on the bolt.
Thanks for the video... I did this for several broken studs on my F150 4.6L... worked for 4 of them but one was more than 1/4" deep and had a divit in the head on the edge of the hole. That caused metal to pool and col there and prevented it from spinning out. tried more than a dozen times, even using a carbide burr to bevel the hole so it would have more room to turn. Ended up removing motor mount bolts and jacking up engine to get enough room to drill. After breaking a couple of bits I got a hole started and then switched to a "left hand" twist drill and part way through the bit caught and spun the loose stud right out! SUCCESS!! Your and other videos gave me the confidence to tackle this myself...That and the fact that 2 local shops refused to touch it themselves, too chicken to even tackle it.
Just love this video! You're an excellent mechanic and If I haven't lived in Sweden I would drop by you shop with my truck! Wondering... do you have 3 arms or something? How the f*ck did you manage to film all that while you were working at the same time? ;-)
I have a 2005 Dodge Ram 2500 5.7 Hemi with four broken bolts on each side of the exhaust manifold. On other trucks I have drilled them out what a nightmare. This time I tried your method and it worked. Got all of them out. Had to go through a bunch of 3/8 nuts, because they don't hold every time, so I had to reweld a new nut. On the last few I heated the broken studs until they were cherry red and then welded the nut, those came right out. Thanks.
Quick question, did the customer say whether the noise went away after it warmed up or did it stay constant? I'm having a similar noise on my 09 ram but the noise goes away after warming up. Great video and looking forward to a response!
Kyle Swiger the sound will quiet down as the manifold heats up and expands, i cannot believe dodge hasn't fixed this issue yet...i refuse to buy another dodge ever
stringb3an I,m sure it's fixed, I have a 89 Mallard Sprinter 30ft Chevy 454c.i. that are notorious for broken exhaust manifold bolts and 28th a eighth inch clearance hard to get to you almost have to remove engine just to do tune up and ive been putting it off but will take care of it when were past this lovely -30F weather, makes that dang ticking noise been doin it for 5 yrs.
RAM TRUCKS Fords 5.0L doesnt have exhaust manifold problems. They have big beefy studs and nuts. Haven't seen one that's leaked yet, and I work at a Ford dealer. At least Ford fixed the problem. Ram just keeps putting crappy manifold hardware in 😂
Another in the bag of tricks are left hand helix drill bits. Snap On makes a set of five smaller sizes and Cle-Line makes them as well. They work if you have to go the drill out method. Enjoy your vids. Keep up the good work.
My 03 ram 2500 transfer case drain and fill plug was rounded off. So I got a bolt and welded on it with my harbor freight flux core welder. Worked like magic! I got a crown Vic with broken exhaust manifold studs and I'm not looking forward to it but hopefully all goes well with this method. Thanks for the video!
As a diesel mechanic and watching some of Scotty Kilmers videos if he's been a 'master' mechanic for over 35 years as he proclaims, do you think its somewhat questionable that he works out of his driveway? Witnessing his hacks, bodge repair methods, careless attention to detail and overall mediocre attitude I'm surprised he hasn't been the cause of someone's death. That's before I even pass comment on his over loud in your face voice and the demeanour of someone who's bipolar and possesses the capability to self destruct at any moment. Needless to say I'm not a fan of his work, when questioned he banned me from making comments on his videos. This channel is what automotive servicing and repair should be. Positive attitude, good work ethic neat and professional repair. Not some stoned hippy from the 70's rolling around on his driveway yelling and shouting at a car terrifying the neighbours.
Scotty's good entertainment but must agree with your assessment of his method and you should not be banned for questioning. I have watched many an ETCG video and he's got it down!!! I wonder what Scotty's tv show was like, when he had it ?
foxdmulder maybe its possible when he finds a car he could make a video on, he asks the customer for consent, maybe even gives them a discount, and takes it home to his driveway to do the work? so that would be 1 out of a hundred per week depending the size of his shop.
Before you call Scotty out on his dubious repair methods you probably should understand that a lot of people work from their driveway or a small shop. There's good money inside work. I meant to say in working on the side. Just cuz you're a diesel mechanic doesn't make you smarter than anybody else... US Air Force turboprop mechanic check in in
I did my last manifold today. 04 F250, V10 pass. side. Plenty of room. Cut heads off bolts and i had the bolt sticking out to work with. Got 9 out with no problems. One bolt broke years ago and was about 1/8" in head. Tried drilling it and was off centered. Welded washer and filled in hole,then welded nut on washer and removed very slowly. Replaced manifold and used studs instead of bolts. No more manifold in my shop. Maybe chevy/gmc only. You're still young and have patients.
Success! I removed four broken bolts from the one side I was doing on my 2005. One was very stubborn and took five tries. The last time I jarred it with the blunt tip of an air chisel right after welding the nut on. It turned right out.
Thank you soo much for this video, just had to replace the gaskets on my 2005 hemi and lucky me, two bolts had snapped heads and three of the studs broke. Your guidance was invaluable. Thank you !
Great job. I've never been the greatest with exhaust manifold work, but after watching some of your manifold jobs I've learned a lot of new skills. The oxy torch is a must though. Old school technology, but nothing works better. Best tool I own!
I’m Chrysler certified and have done these broken exhaust bolts on the hemis numerous times. Watching this is going to save me 2 hours of reverse extraction with a drill. Thanks man! 😀
have a 2006 mega cab 4x4 with the 5.7 hemi, same issues..... followed the video....and easily removed the two broken bolts with welder and nut. Thanks for the video....this way worked super for me
I need to say "thank you". I have been enjoying your videos from time to time. This one in particular and especially was gold. I have older vehicles in the family driveway and every one of the at some time develop exhaust manifold leaks from broken bolts. The Dodge Ram had 3, the Dakota had 2, the new2us F150 has one, and the Chev Tahoe I am working on right now has 4 broken bolts. Tomorrow I will be wheeling out the welder to get the 4 bolts out of the Chev 5.3. I have used and continue to use your weld a nut on technique. It really works, and works well. Challenge on the Chev is 2 of the bolts are broken off about 1mm inside the head. Those will be tough to get a bite on, crossing fingers. The other two bolts are broken flush with the head. Anyways, great video and wanted to say that it has helped, alot. Thanks!
I just did another one of these the other day. Its a very satisfying fix once done. I sent out the manifold to the machine shop with some rotors. They charged me a whopping $45 to cut 1 manifold flat. I was expecting like $15-20 bucks. Oh well, they did a good job and the truck is quiet now.
The heat shield on my 2018 1500 Hemi is loose on the passenger side at the rear. 70k Km and just starting snapping for 30 seconds or so cold start up. Luckily still a warranty item I believe. Thanks for the video saves me from fighting with the stealership about it.
just did this job...had one manifold bolt broken off very deep, couldn't weld a nut onto the broken bolt as it was deep and the mig kept hitting the nut and head. Tried to put a nut on it a few times....gave up and just did weld build up until I could get a set of vice grips on it....worked well....thanks for the info SMA...much appreciated
Great video! Completed this job myself on my 2016 Ram 1500 and welded the broken bolt to a nut as shown in your video, it worked! Thanks for sharing your knowledge!
