rather super irritated

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doood

Amateur Mechanic
Sep 24, 2020
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Just venting:

How much more would it have cost GM to use something other than mild steel for the LS header bolts? Kill those aholes that didn't use a better base metal; most came out with a bit of torch on the aluminum, but GODDAMN 3 broken? I thought I was the man (bad *ss) for reversing-out the first of three broken header bolts, before I subsequently snapped three drill bits and broke off a tap in the head... Yeah, I'm pissed, but the fall-back position is drilling it out way oversized and threading an insert into aluminum, so I should get over it, right? It'll be ok when I attack it again next week, right? BTW one of those header bolts was snapped before the junkyard pick. Grrrr. Listen, I'm an office worker that is trying to build a respectable g-body: it only gets worse from here... am I right? Valentines day? Sacrificed $100 to please the gods - would really feel warm and fuzzy if these bolts came out.
 

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melloelky

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Oct 22, 2017
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Just venting:

How much more would it have cost GM to use something other than mild steel for the LS header bolts? Kill those aholes that didn't use a better base metal; most came out with a bit of torch on the aluminum, but GODDAMN 3 broken? I thought I was the man (bad *ss) for reversing-out the first of three broken header bolts, before I subsequently snapped three drill bits and broke off a tap in the head... Yeah, I'm pissed, but the fall-back position is drilling it out way oversized and threading an insert into aluminum, so I should get over it, right? It'll be ok when I attack it again next week, right? BTW one of those header bolts was snapped before the junkyard pick. Grrrr. Listen, I'm an office worker that is trying to build a respectable g-body: it only gets worse from here... am I right? Valentines day? Sacrificed $100 to please the gods - would really feel warm and fuzzy if these bolts came out.
that is frustrating,i know this is zero help but mild/carbon steel to aluminum is the lesser of two evils in that exhaust/dissimilar metals department actually.ford went that route with stainless manifold hardware and with the constant heat cycling of the cast manifold-stainless hardware relationship it's an absolute nightmare.again i know this is no help but it might be worse.in my opinion that $100 was money well spent on this holiday of all holidays..
 
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64nailhead

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Dec 1, 2014
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FWIW, the bolts don't break because of poor quality. Manifold bolts have to be of a material that expands and contracts at the same rate as the manifold. It's not as easy as one would think.

Anyway....bust out the welder and leave the drill and tap for someone else. A 220 welder is even better, but a 135/145 Miller, Hobart, Lincoln, etc. will get it done, just might take a couple of tries (be sure to unhook the battery before welding).
 
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ssn696

Living in the Past
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Jul 19, 2009
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Wait...did you not know that those OEM head bolts are torque-to-yield? Exhaust manifold bolts are yield-to-torque?
 
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mikester

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Pretty sure thats a common issue with those motors especially the 5.3s. My old '03 Tahoe had a nasty exhaust leak but for some reason I think they were studs and not bolts. I might be wrong about that since it was a long time ago. I wasnt about to mess with them. I took it to the local Chevy dealer. I'd rather see them fight with that crap.
 
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81cutlass

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My Rainier 5.3 daily had one broken manifold bolt when I bought it at 180k and slowly broke another 1 about every 10k miles until I had 3 or 4 broken ones and it had a nasty tick when cold. Finally I tackled the project.

I did the weld a nut to the broken stud trick and they all came out pretty easy. I think I had 5 of 6 broken on the drivers side and 3 of 6 on the passenger side after I pulled both manifolds. A few broke right under the bolt head and was able use a vice grip to remove the ones with a little stud protruding (word has it knipex brand german made channel lock pliers are the best because they have hardened sharp jaws and dig in harder as you apply torque). The other 3 or 4 had to be welded on and they came right out.

The welder helps burn the loctite and rust out of the bolts and they spin out nice when warm!
 
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81cutlass

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And it's frustrating but it's not just a GM thing. My buddies 04 5.7 hemi dodge had the same issue and so do 4.6/5.4 fords.
 
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Streetbu

Know it all, that doesn't
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May 22, 2011
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Ford modular motors in the F series are known for it too....
 
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08Malibu

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Feb 9, 2014
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I have like 3 on my 05 Sierra as we speak. I have to tackle them when it warms up. Not looking forward to it.
 
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