Dodge Cummins Diesel Forum banner
1 - 3 of 3 Posts

·
Registered
Joined
·
49 Posts
Discussion Starter · #1 ·
I was taking the exhaust manifold off my grandfathers truck yesterday and broke some of the bolts in the head. It looks like i am gonna have to pull the head to pull the studs out that i broke for manifold. What kinda trouble am i getting myself into? Do i need to replace the head studs or can they be reused? What head gasket should i go with to replace the stocker. He uses the truck to pull his fifth wheel. Thats it. It has a 150 horse superchip and plans on 100 horse injectors in 20,000 miles. I dont think it will need studs for that but not sure. Any help would be great. Truck is a 2005 3500 4x4. Thanks
 

·
Registered
Joined
·
1,923 Posts
To pull the head can be a bear. Need to drain the coolant obviously. Removed the head bolts yes you can reuse them if none have stretched. Need to disconnect the fuel system. Id surest removing the injectors so you don't damage the tips since they sit bellow the bottom of the head. Push rods can be a pain with the back 4. Use a genuine Cummins head gasket. Take the old one with u so they get the right thickness. It could ne an easy two day project to fix this or a very long one day. Any reason you can't remove them with the head in place? There is alot of room on that side even more if u remove the wheel well. As for injectors he should NOT get 100 horse sticks. The truck can't handle it they will cause very excessive egts and will drain his fuel rain. He will need an upgraded injection pump, bigger turbo, and different cam to successfully run those injectors esspecialy towing. Most you can go on a stock system is 50 or 60 horse sticks and even those get things hot. Just food for thought. Good luck with the exhaust bolts those can be massive [email protected]$
 

·
TECH SPECIALIST
Joined
·
5,876 Posts
should be able to drill and Easy Out the exh. manifold studs except for maybe the very back one.
use a right angle drill head adapter, US made cobalt HSS drill bit and a USA made spiral bolt extractor.
Mac, Snap-On or Desco, no Chinese krap that snaps off in hole.



drill the hole for extractor. spray bolt hole with PB Blaster and put a PB Bl soaked rag up against the hole held there overnight with wire or stick.
let soak 24 hrs and remove.
 
1 - 3 of 3 Posts
Top