J5Murph

I decided a few weeks ago to spend a little time and money and buy myself some new BBK shorty headers. Well, I started the install myself and came across a broken exhaust manifold bolt. I didn't really want to carry on so I took it to an exhaust shop and told them to fix it and they made it worse so I decided to take it to a friend of mine shop. Well another week went by and he can't get the bolt out either. So I'm stuck with two options. Replace the cylinder heads or do an engine swap. If I did an engine swap I wouldn't put a 5.4 back in the truck.

The truck as it sits is a 2003 5.4l FX4 with only 113k miles on it. Everything is perfect on the truck minus the engine.

So my question is what engine could I put in as an upgrade other than the stock without having to replace the transmission and transfer case and so on. Has anyone done this before? If so what success and problems did you have?

FallGuy44

So neither shop was capable of drilling a bolt out?

jkenprice1

I'd spend some more time trying to get the bolt out. That would be a lot cheaper, and your motor should have a lot of miles left. Quite honestly, if getting a manifold bolt out is a problem, you don't want to start an engine swap with a different size motor.

BlakeA

Lightning 5.4 swap
V10 swap
Built 4bt Cummins swap

I'd get a second look though. Do you have any pictures of the damage?

Holicori

I agree.

Seriously? You want to do an engine swap just because of ONE broken exhaust manifold bolt?

****, I have 2 broken bolts on my exhaust manifold right now...no leaks, no problems (although I do plan to fix it in January).

It sounds like 1) you are just itching to do some work on the truck...regardless of what it is. And more importantly 2) it sounds like you shouldn't even mess with swapping an engine (unless you're paying somebody).

If you freaked out over a single bolt (which those bolts are soft as hell), and took it to several shops....then you shouldn't be trying to swap, especially swapping different engines.

And keep in mind, I'm extremely adamant and supportive of people doing their own work...and even doing things just to learn even if they do mess up. I'm not one of those forum guys that bashes people telling them they shouldn't change their oil without an ASE master tech cert.

mbb

If any stub is protruding, you can weld a nut to it as well as using ez outs. What did they do to make it worse?

screamineagle

Been driving my truck for 3 years with a broken stud. Replacing the engine never crossed my mind

J5Murph

So the issue with the bolt was that it had previously been helicoiled and the bolt was broken inside the coil Below the head surface. the exhaust shop tried to get it out and resorted to welding a bolt to the old bolt which snapped at the weld joint. this has made it impossible to get a drill bit or easy out to stay on track with the weld bead now on the bolt end which brings me to my options of replacing cylinder heads or engine for what started as an exhaust manifold replacement

Holicori

Just leave it honestly.

as long as there aren't exhaust leaks,...which I doubt...then you're fine.

And theres always a way. You could take the manifold off, grind down the weld a bit, and then drill it. You could even overdrill it and tap it (I would not recommend this). But, that's kind of absurd to fuss about just that bolt.

mbb

not sure how they welded a bolt below the head surface to another.

What is sometimes done is to put a washer over the bolt, and weld the washer to the broken bolt, then weld a nut to the washer

In any case, fine point on a die grinder or dremel can make a starting depression for the drill If a punch wont. The helicoil gives you a larger margin for error too. The whole thing may come out and you clean up the helicoil threads and put a new one in.

Its not uncommon to try to weld on several times before you get something out.