How to Remove Stuck Header Bolts

Because exhaust manifolds and headers are made of iron, they are particularly susceptible to rust. Rust by itself usually doesn't present a problem for exhaust components. However, removing rusted exhaust bolts can be a daunting task. Thankfully, a combination of lubricant, heat and muscle will remove all but the most stubborn exhaust manifold and header bolts.

Things You'll Need

• Penetrating oil
• Pencil torch
• Locking pliers

Instructions

1. Spray the head of the bolt, where the bolt enters the header, with penetrating oil. Let the oil soak into the bolt for at least two hours.

2. Heat the bolt head and the area of the manifold immediately surrounding the bolt for 30 seconds with a propane "pencil" torch, commonly available at hardware stores.

3. Grasp the head of the bolt with locking pliers while the bolt is still hot, then twist the bolt in a counterclockwise direction until it breaks free.

References

• Mustang Monthly magazine; How to Restore Exhaust Manifolds; Donald Farr; November 2009