Advice on frozen exhaust manifold bolt

[Beekeeper]

Didn't see an older post on this but I figure I can't be the only Mopar guy to experience this.

Trying to get a HP manifold off and one of the "sleeve nuts" is frozen. I've tried the usual rocking back and forth, penetrating oils, tapping it with a hammer, etc. but can't get it free. I've been using a 6 pt socket and the head is pretty close to rounded off now. I'd even be willing to remove the head and work on it on the bench except the manifold hides all the lower head bolts.

I was going to try heat next but I'm worried I'm screwed. What do I have to do short of cutting the manifold off with a torch?

I am considering welding a new nut to the head just so I have something solid to get a wrench on. Any thoughts on this? I can almost picture the new nut not fusing well to the rusty bolt head and just twisting off. Just thought of trying to get in that tight space with a welder makes my head hurt.

Thoughts anyone?

[734406pk]

Didn't see an older post on this but I figure I can't be the only Mopar guy to experience this.

Trying to get a HP manifold off and one of the "sleeve nuts" is frozen. I've tried the usual rocking back and forth, penetrating oils, tapping it with a hammer, etc. but can't get it free. I've been using a 6 pt socket and the head is pretty close to rounded off now. I'd even be willing to remove the head and work on it on the bench except the manifold hides all the lower head bolts.

I was going to try heat next but I'm worried I'm screwed. What do I have to do short of cutting the manifold off with a torch?

I am considering welding a new nut to the head just so I have something solid to get a wrench on. Any thoughts on this? I can almost picture the new nut not fusing well to the rusty bolt head and just twisting off. Just thought of trying to get in that tight space with a welder makes my head hurt.

Thoughts anyone?

I go through this delema all the time on marine diesel engines so I feel your pain! Can you post a pic of this thing so I can tell what your up against? It sounds like you have some welding equipment available which is a major plus. May be I can help you with this.

[1 Wild R/T]

Welding a nut on is a good plan, I've done it many times... I'd use a 1/2" or even a 5/8" nut... The big cavity of a larger nut will allow a good puddle & the heat that transfers to the stud will help free it... You need to try breaking the stud free while it's still hot..

[Kapteenikosmos]

Heat will break it loose, either with a torch or just welding a big nut over the existing one as suggested above. According to my limited experience you have enough heat when the sleeve nut starts to radiate red color. I became a believer of heat when I managed to remove absolutely horrible bolts from my salt digested Lincoln exhaust.

[Beekeeper]

I think I will try welding a large nut on since this one is nearly rounded off. Sounds like all that heat will help too

[HP_Cuda]

You can start with the easiest first.

Try some Kroil, let it creep in and give it some time. Has worked quite the charm over the years.

Otherwise add heat and take that sucker off.

[plumcrazzy]

Moderate heat will always help. Just make sure you get good heat transfer down the length of the bolt. Heat will cause expansion of the bolt which should crush the rust and/or debris. Let the bolt cool and it should free up when it shrinks back to size. Good luck.