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Removing Heads - Stuck exhaust manifold bolts


ant.xlt.96

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Tearing down the engine in my 96 4.0 OHV v6 to replace head gaskets. I've got the passenger side head removed, but the driver's side is a PITA! I've been able to remove 2 of the 6 bolts going into the head, but don't have enough clearance with my 1/2" drive breaker bar to get the leverage it needs to budge. Didn't have issue with the passenger side. No broken/ snapped bolts at all. Been soaking them with PB Blaster, went in from the wheelwell, hammered at the rust...nothing. :shout:

The clearance issue is with the steering column, I think? (This is my first tear down past the lower manifold, so I'm still familiarizing myself with everything under the hood.)

Any tips or leads to a specific tool would be appreciated. I'm working on it in the street in front of the house, so I'd like to get it apart and back together asap. I also don't have access to a torch or tools to drill out a busted bolt.

Thanks guys!
 


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black_demon69

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Tearing down the engine in my 96 4.0 OHV v6 to replace head gaskets. I've got the passenger side head removed, but the driver's side is a PITA! I've been able to remove 2 of the 6 bolts going into the head, but don't have enough clearance with my 1/2" drive breaker bar to get the leverage it needs to budge. Didn't have issue with the passenger side. No broken/ snapped bolts at all. Been soaking them with PB Blaster, went in from the wheelwell, hammered at the rust...nothing. :shout:

The clearance issue is with the steering column, I think? (This is my first tear down past the lower manifold, so I'm still familiarizing myself with everything under the hood.)

Any tips or leads to a specific tool would be appreciated. I'm working on it in the street in front of the house, so I'd like to get it apart and back together asap. I also don't have access to a torch or tools to drill out a busted bolt.

Thanks guys!

either pull y pipe and pull exhaust manifold with head and remove after head is removed. or use heat choice is yours
 

WarHawk-AVG

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I have seen this around several places

50/50 mix of the cheapest ATF transmission fluid and acetone

http://www.garagejournal.com/forum/showthread.php?t=182271
Homemade Penetrating Oil

For All of you Mechanic's and Self doer’s out there.
Penetrating Oil - interesting
This was in one of the Military Vehicle Club newsletters

Here is an interesting finding on Penetrating Oils
Recently “Machinist Workshop Magazine” did a test on penetrating oils. Using nuts and
bolts that they ‘scientifically rusted’ to a uniform degree by soaking in salt water, they then
tested the break-out torque required to loosen the nuts. They treated the nuts with a variety
of penetrants and measured the torque required to loosen them.
This is what they came up with:
Nothing: 516 lbs
WD-40: 238 lbs;
PB Blaster: 214 lbs;
Liquid Wrench: 127 lbs,
Kano Kroil: 106 lbs
(ATF)/Acetone mix (50/50): 50 lbs.

This last “shop brew” of 50% automatic transmission fluid and 50% acetone appears to beat
out the commercially prepared products costing far more.

NOTE: I can't personally vouch for the results, 'cause I haven't read the magazine or tried it yet.
http://www.youtube.com/watch?v=2WuVBFTzoKc

Also I have found those ratcheting wrenches absolutely INCREDIBLE for tight spaces...
http://www.sears.com/tools-wrenches-ratcheting-wrenches-sets/b-1214364371

There is also the trick to get more leverage from a standard combination wrench by locking another one in the jaws of the other...
 
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alwaysFlOoReD

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Removing the steering column is a possibility as well. As mark88 said " it's not that hard ".
 

downer

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a 3/8 ratchet, wobble socket and cheater on it. pulling the hood off helped too.
 

adsm08

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If I am pulling a head to do head gaskets I leave the manifolds on them and just unbolt the manifold from the y-pipe. It's less work and gives you a nice handle.
 

Andy D

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If I am pulling a head to do head gaskets I leave the manifolds on them and just unbolt the manifold from the y-pipe. It's less work and gives you a nice handle.
After my first head R+R in 30 yrs, this is gonna be my MOP on the next one I do. To the OP. Why do you feel you needed to replace the head gaskets? Is this a common old 4.0 thing? Did it over heat? :icon_confused:
 

bobbywalter

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yeah....the 4 liter is called the 4 leaker in some areas. they get low on coolant and pop gaskets pretty easily post fast burn head design...




i do it the same as adsm. only pull manifolds when they are broke....and the passenger sides bust alot.
 

ant.xlt.96

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Thanks for all the tips guys! I tried them all and once the exhaust manifold bolts started to feel like they wanted to round off I went for the Y. Lucked out and both bolts came out easy. Just about to attempt to pull off the head. It's loosened up and ready to go. :icon_hornsup:

After my first head R+R in 30 yrs, this is gonna be my MOP on the next one I do. To the OP. Why do you feel you needed to replace the head gaskets? Is this a common old 4.0 thing? Did it over heat? :icon_confused:
Hey Andy, I was having some major issues with coolant loss that turned into a white smoke exhaust problem. Went in earlier this month and changed out the lower manifold gasket, but had a hunch after I did that job that the real problem was the left head after finding a drip from the gasket to the oil pan. No mixing of coolant and oil, so wanted to change out gaskets before things got worse.
 

black_demon69

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Thanks for all the tips guys! I tried them all and once the exhaust manifold bolts started to feel like they wanted to round off I went for the Y. Lucked out and both bolts came out easy. Just about to attempt to pull off the head. It's loosened up and ready to go. :icon_hornsup:



Hey Andy, I was having some major issues with coolant loss that turned into a white smoke exhaust problem. Went in earlier this month and changed out the lower manifold gasket, but had a hunch after I did that job that the real problem was the left head after finding a drip from the gasket to the oil pan. No mixing of coolant and oil, so wanted to change out gaskets before things got worse.
Now go and have your heads checked for flatness and cracks:icon_thumby:
 


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