I have had a slight exhaust leak on my 1995 Chevrolet 2500 since I bought it and decided I was going to repair it today. It had a broken exhaust manifold bolt in the head which was about the easiest one to get out (front drivers side). So I tried to drill it and EZ out it. Yeah right - that bolt laughed at every bit I threw at it. So I figured I would remove the manifold and go at it that way. The rest of the bolts came out with minimal work and I was able to get the broken off stud out with some vise grips. So far so good. So then I tried putting the manifold back on and got all the bolts, but the back one which decided it was going to fight me - for over an hour. I finally gave up and decided to take the manifold loose from the y-pipe because it felt like that was what was binding it. This is when the real fun began...all three collector bolts broke so I had to remove the manifold again to drill them bitches out. I was able to save the threads on 2 of the 3 after A LOT of drilling and tapping. The 3rd one whooped me and is getting a bolt with a nut on the other end. Got the manifold back on (after another battle) and the stupid bolts that broke off with the flange are so seized on there that I am going to have to die grind them off. It started raining or I would still be out there. I learned another good lesson today - leave the exhaust work to the exhaust shops!!!!!

 

oh yeah... sounds like you did better than i usually do though. thats the worst part of pulling transmissions... getting that damn crossover pipe off.

 

I hear you on that! Now with my plasma cutter I just laugh and melt that stuff like butter!

 

Well I am glad I am not alone. Misery loves company. I was so careful too. I have been spraying everything with PB Blaster for the last week, I used a 3/8" impact and didn't even hammer it too hard with that little guy. This truck is a southern one too, so it has zero rust. I don't know how the northern guys cope with the rust factor also! My wife came out when I was in the middle of one of my many cursing sessions today - I told her I wish I could figure a way to haul the boat and trailer with my motorcycle, I would sell all my vehicles. I was, of course, just raging - I think it's just a part of wrenching.

 

Heck yeah Ive had my moments where I have even pushed my little SUV off the jacks cuz I was so mad! Wasn't worth it but workin on the Drilling Rigs teaches alot about gettin mad at the iron. So now I have mellowed out and just figure out ways around problems. Shamrock I wonder if a whole stainless steel system would prevent all this? Im thinkin of doin that to my truck since it will be constantly worked on.

 

Or even better, some anti-sieze dope on all connecting metal!

 

Got it all together and it was a better day. Things went smooth and my exhaust leak is fixed! I even had enough energy to put a new set of spark plugs, wires, cap, and rotor. It is running like a champ now! And yes RuffNeck I used a lot of antiseize. Thanks for letting me vent yesterday!

 

No problem. Im sure just a few bruised knuckles will be ok for a finished task!