Anyone ever have an exhaust manifold bolt randomly break? - Dodge Cummins Diesel Forum
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post #1 of 15 (permalink) Old 11-12-2019, 12:22 AM Thread Starter
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Anyone ever have an exhaust manifold bolt randomly break?

04.5, all stock. Nothing's been touched since I've owned it (2012...so a minute). 197k miles. Only semi-recent thing I did was put a turbo back exhaust on the truck about 2,500 miles ago, but obviously only had to unclamp the one clamp on the down pipe. Anyways. Truck got a weird noise at various RPM's, and really sounded like it was turbo related. I inspected it, and the two most rearward (firewall) bolts just broke off. I can see the hint of carbon build up around it as a result.

What would cause this? Measuring the amount of bolt left, it looks like the bolts probably broke almost flush with the head. What gives? Looks like a right angle drill is a must have to try and drill these out. I'm just perplexed on what in the world could cause this, out of blue? Surely I can't be the only one?


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post #2 of 15 (permalink) Old 11-12-2019, 01:56 AM
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The stock exhaust manifolds are known to warp, crack and break manifold bolts. It's pretty common. There are several write ups on the forum for replacing broken belts all the way to replacing the manifold with a better aftermarket part. You can find several threads on the topic using the forum search function. Some have had luck with replacing bolts with stronger aftermarket studs. For many, it seems that once the problem starts, it becomes a continuing issue.
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post #3 of 15 (permalink) Old 11-12-2019, 06:49 AM
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Not on my Cummins so far, but lots of other vehicles engines
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post #4 of 15 (permalink) Old 11-12-2019, 07:56 AM
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no not randomly, i had an exhaust manifold bolt break. my truck decided it was time for some kickback and purposely broke the bolt all the way back by the firewall. some pain & suffering dished out, i promised it i would be genteler with it off road. we reached an agreement, no more broken exhaust manifold bolts from it and no more higher speed runs on mtn dirt roads. so far so good...

if it were random, it would have been easier to access.


also fwiw, it started shedding the bolts holding down the plastic engine cover, not broken, just missing

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post #5 of 15 (permalink) Old 11-12-2019, 09:07 AM
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OP. You changed the exh system .
Is it hung properly ?


Might need

centering fixture of some kind for drilling
Kroil penetrating oil ( the best , please change my mind )
Left hand drill bit ( s ) a must IMO
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post #6 of 15 (permalink) Old 11-12-2019, 09:15 AM
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adding my experience fixing my busted bolt...

important stuff starts from here

https://www.cumminsforum.com/forum/3...l#post29055537
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post #7 of 15 (permalink) Old 11-12-2019, 11:20 AM
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320,000 miles and no broken bolts. I'm running a near 400 HP tune also.

Man this pick up runs great!!!
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post #8 of 15 (permalink) Old 11-12-2019, 12:12 PM
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Quote:
Originally Posted by 24hrsparkey View Post
OP. You changed the exh system .
Is it hung properly ?


Might need

centering fixture of some kind for drilling
Kroil penetrating oil ( the best , please change my mind )
Left hand drill bit ( s ) a must IMO
That did not pan out with the setup I had... when ever the bit grabbed, it would loosen the chuck. It was using the flexible extension with a cheap bit chuck though to get it back in there. There was a dewalt version of it but it was 5x the cost, that might have worked better.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 424k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #9 of 15 (permalink) Old 11-12-2019, 12:43 PM Thread Starter
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Thanks for the link Steve, I ran across that when I was doing some googling last night.

Had the thought of doing some heat cycles with Kroil before attempting the project - understand that there's not a load on the bolt (now stud) anymore, so hoping it doesn't fight me too much. The truck is clean, and the rest of the bolts are pretty dang clean, especially given the age. I've seen far worse. I was thinking of using Kroil, then starting it up and letting the engine come up to temp, spray a tad more after it's warm, and doing that a couple of times in hope that it'll creep into the threads and make removal that much easier.

Here's my initial plan of action, let me know if I'm off the mark.

- Kroil the hell out of it.
- Copy Steve's drill guide and try to extract the studs with everything in place
- Hope for the best and go from there, and remove the manifold if I have to.

2004.5 2500 CC SB, 4x4, 48RE, 4.10s, Hypertech Programmer, 305/65/17 BFG A/Ts, spray in bed liner, 08+ steering upgrade, B&W Turnoverball with Companion slider, Firestone air bags, 142k miles and counting
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post #10 of 15 (permalink) Old 11-12-2019, 12:57 PM
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if its all clean like you mention... you probably dont need Kroil... Make up a jig like I did to guide the drill bit, drill a small pilot hole and then use the easy out. Mine was not tight at all and came right out.

Look at the dewalt attachment and see if that will be able to reach back into the rear bolt, if you decide to go with reverse thread bits. Either way you will need a flex adapter to get back in there. I used it plus a cordless drill...

Feel free to PM me if you have any questions on what I did.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 424k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #11 of 15 (permalink) Old 11-13-2019, 04:45 PM
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Mine started with a blown exhaust manifold gasket at the back cylinder. I thought it was a good opportunity to replace with an aftermarket 2 piece manifold. I bought the DPS. While removing the stock manifold, my mechanic broke one of the bolts. He called me to warn me of extra time it would take to get the bolt out. When, I picked up the truck, he told me he was able to remove it with his fingers. I guess the warped manifold put so much pressure on the bolt while removing it that it broke. With the manifold off, no pressure and was simple to remove. I hope you get lucky like I did.

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post #12 of 15 (permalink) Old 11-14-2019, 10:41 AM Thread Starter
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Quote:
Originally Posted by njmurvin View Post
Mine started with a blown exhaust manifold gasket at the back cylinder. I thought it was a good opportunity to replace with an aftermarket 2 piece manifold. I bought the DPS. While removing the stock manifold, my mechanic broke one of the bolts. He called me to warn me of extra time it would take to get the bolt out. When, I picked up the truck, he told me he was able to remove it with his fingers. I guess the warped manifold put so much pressure on the bolt while removing it that it broke. With the manifold off, no pressure and was simple to remove. I hope you get lucky like I did.
The more I look at it, the more I'm inclined to just pull the manifold. More work...yes. But I'm thinking it may be one of those things where it will take more time, but be far easier as a whole to just pull the turbo and manifold out and give myself that much more room to work.

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