What's the best way to remove solidly rusted bolts from marine engine exhaust manifold?

Question:
engine is a '91 GM 350 V8 fresh water cooled.

Answers:

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From my experience, bolts on engine exhaust manifold are likely to break when you try to remove them, and the bolt loosening fluids in this case rarely work. Of course, before attempting anything drastic (like drilling out), try less invasive methods - the bolt loosening fluids from a car parts store.

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Please, be patient when using the fluid - it may take a couple fo days (if your project is not urgent).

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Otherwise, there are special kits in the car parts stores for drilled out bolts. The kits contain inserts to match the original size of the bolts.
When you install new bolts, please use special thermal grease (graphite paste of some sort) to make the job simpler next time :)

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If buckets of penetrating oil and a screw extractor don't work, the you may have to drill it out and re-thread it.

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You might first try thoroughly soaking them with WD-40 in an attempt to loosen them. If that doesn't work you might consider drilling them out and replacing the bolts altogether with new ones.

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Use a liquid called penetrene on the bolts use plenty then strike them after soaking with the penetrene for a couple of days . The striking should be shart raps not full on strikes then use lock on pliers or stillsons or whatever fits the bolts also some oxy or gas heating can help.

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I have removed rusted in manifold bolts in a couple of ways. One is to use a very good penetrating oil, there are several on the market, and soak to rusted bolt area with it. tap the head of the bolt with a hammer, you might have to use a large punch to reach the bolt, and then more penetrating oil. let it stand and do the same again, using plenty of the penetrating oil and taping. use a 6 point socket on the bolt not a wrench as the wrench or 12 point socket will round the head. Use a steady pressure in both directions alternately but don't get too hasty, you want to loosen things up so the oil can do it's thing. Persistence will pay off, just try not to break the bolt. Have fun.

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Frank

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anytime you attempt to drill out a broken manifold stud,the drill always wanders into the head itself so it becomes necessary to drill an over sized hole.if all else fails cut the nut off with a chisel or grind the heads off,remove the manifold,this will leave you with about an inch of the bolt shank protruding,use a pipe wrench or vice grips to remove,you can also heat the shank with a torch.you can also wield a larger nut onto the shank,the heat from the wield loosens the threads[works everytime]

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Try heating them up. Also sometimes tightening them up a little will crack the rust.

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Try and find some "AEROKROIL" it's the best penetrating lubricant know to man, it can seep into places that are 2000th of an inch, give it 24 hours to work after application.
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