Factory exhaust manifold bolt removal – Banks Power Ford Motorhomes: (Gas ’93 - 98 7.5L Class-A) PowerPack System (Class-A, Ford chassis, non-cat) For Use w_ 460 EFI Engine User Manual
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Because of a condition inherent in the
factory design, the exhaust manifolds
may crack the manifold-to-head bolts
as manifolds undergo changes in length
from expansion and contraction. In some
cases, these forces may also crack the
exhaust bolt bosses on the cylinder head.
Cracked bolts will not show any external
damage, but bolt heads may break off
upon removal.
We recommend that you do the
following to minimize the possibility
of broken manifold bolts.
1.
Apply a penetrating oil (such as Liquid
Wrench) to the area where each exhaust
manifold bolt enters the cylinder head.
2.
If some bolts turn more easily than
others, remove these bolts first. This may
reduce stress on the tighter bolts.
3.
The use of an impact wrench is
recommended, when available. The
hammering action of the impact tool
helps loosen the bolts better than the
steady pull of a wrench handle.
If a manifold bolt does break off,
it may be removed by one of the
following methods.
1.
If there is enough thread remaining
on the broken bolt to install two nuts, it
may be possible to jam the nuts together
to turn the bolt. Tighten the nuts against
each other, then turn the bolt by turning
the inner nut counterclockwise.
2.
If there is some thread protruding
from the head, but not enough to install
double nuts, it may be possible to grip
the bolt with a tool such as a Vise-Grip
pliers.
3.
If the bolt has broken off near or
below the flange surface of the head, it
may be drilled and removed with a screw
extractor, such as an Easy-Out. Make
sure you drill the pilot hole in the center
of the broken bolt with the proper size
drill for the extractor used. If the hole is
not on center, it may cause the extractor
to bite into the threads in the head,
preventing the extractor from turning.
For severe cases, a bolt extracter
kit may be ordered from Gale Banks
Engineering (P.N. 97000).
FACTORY EXHAUST MANIFOLD
BOLT REMOVAL