Okay guys i decided to replace my exhaust gasket and my flange gaskets. They needed to be replaced. So i took of the 3 flange gasket bolts, 1 of them snapped and the remains are in the bottom of the header. When removing the exhaust manifold from the head, another 2 rusty bolts snapped. now i was pissed.
when i removed it i was happy because the 2 that snapped was not the ones on the head it self. these were attached to the header. So i went to Checkers, and bough some easy outs, Did what the instructions said to do and 3 of the easy outs broke. Now i was ready to do some damage but to what? beat the truck up ? so i took a walk to calm down and decided i was going to post this and see what you guys say. Now my truck sounds like a big @$$ diesel. I can now say I TURN HEADS.

SO 3 words.....HELP ME PLEASE.

thanks guys


Myron

 

Easy outs are tricky. You have to be extremely patient or it's very easy to break them, especially when your working on something like your truck where the parts are very rusted and seized.

My suggestion would be to give it another shot with the easy out. Drill a nice pilot hole, and soak the part with some PB Blaster (awesome penetrating lubricant....hahaha, yeah I know it sounds dirty) overnight. The PB Blaster will help the seized peices come loose.

If the easy out doesn't work. Then you're left with a couple other options. You can completely drill out the stuck bolt and re-tap the hole, but this will require a larger stud (not a good option since you'd need to also tap the head for larger studs also.) Or you can heli-coil new threads into the hole once you've drilled it out. That's probably your best option if the easy out doesn't work, but I would definitely get some PB Blaster and soak the crap out of it and keep patiently working with the easy outs if you can.

I would also check these guys out if you just wanted to replace the header. These guys do great stuff with Toyotas.http://www.toyotacatalog.net/M1WebGe...aspx?Class=154

 

btw, here's my old '85 and I also had a '93 Toyota so I know what you're going through. Spent lots of time under the hood and everywhere else on Toyota pick ups.

 

Just drill it out and us some regular bolts instead.

Helicoil would be the right way, but a regular bolt should hold just fine, as long as there's room for the head of the bolt.