Exhaust Gasket leak and stud broke

[HMH2SUT]

I have the same issue myself now. 2005 with 125k... I have 2 broken bolts on the drivers side. Found one bolt head in my driveway, stressed and corroded off...
hopefully i will get a chance to fix it this week I will take pics of the process and post them.

Thanks for the part numbers Easy ED

[HMH2SUT]

a few pics of the manifold with bolt heads missing...






passenger side, is this crack common? like a casting weak point?

[Easy Ed]

That crack is made that way, can see it in pic below, upper manifold.

Also, If I remember correctly, the oil dipstick has to come out to get the passenger side manifold off . One bolt holds the dipstick bracket to the engine block and it the goes into the engine block with a o-ring for sealing. The manifold won't go over the bracket that I could find, like I said earlier, just a bunch of grin and bare it moments to get the manifolds off. (May be because of the heat shield, I do not remember, been a while since I did the work )

Here is a link to my HUMMER page at Photobucket so you can see some of the "parts" and what I removed to get the manifolds out.
http://s639.photobucket.com/albums/u...i/HUMMER%20H2/ Plus other things I have there for reference or for questions that have been asked before.

HMH2SUT, You are welcome on the part numbers

Good luck, Ed

[HMH2SUT]

Decided to start the job now instead of putting it off, realized I had 3 broken bolts on the drivers side so no time to waste... got the driver side manifold off pretty easily. 2 of the broken bolts I can grab with vise grips but of course 1 is broken off inside the head, this coulda been a nice easy job!

Any tips on extracting the bolt from the head?






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[Easy Ed]

Oh Sh!t, that is going to be a problem sorry to say.

Got to use a SMALL right angle drill with a 3/16" drill bit, run it at SLOW speed (bolts are prone to heat treat if you get them hot, hotter than when the motor is running, then you would need a carbide drill bit to cut it), use oil for cutting fluid and once you get through the bolt use a GOOD bolt extractor (not made in China) and hope it comes out, you don't want to know what you will have to do if that don't work.........

One other possible way to try and get it out and this is only if you have a welder and are good at using it, Hold a hex nut over the hole/bolt and go inside the nut and build weld up between the nut and bolt, melt the two together, let cool and hope you can put a socket on the nut and all backs out.

Good luck, Ed

[HMH2SUT]

Easy ed- Its nice to know im not crazy, my first thought was to use a welder but thought that might be over kill...
After going thru my tools I realized I didnt have an extractor or easy out in the size needed. So I tryed the welding method. Everything went as planned on the driver side. The 2 bolts with exposed threads I just slide a 3/8 nuts over and tacked them on. They would have came out with vise grips but this was much easier.
The third bolt was broken just below the surface of the Head. I placed a "fender" washer with a hole just smaller then the bolt hole to contain the weld to the bolt only and not the head. I welded the washer on then a nut and backed everything out...

passenger side is another story... 2 more bolts broke as soon as I tryed to turn them. Tryed the welding method but they are to far below the surface.
looks like I will be buying some new tools tomorrow..

Parts...
Every local parts store had the gaskets, only one could get the bolts but woulda took 3 days. so picked them up from the stealership for $2.50 a piece.

[johndjmix1]

Why not replace the bolts with stainless steel to avoid corrosion?

--John