exhaust manifold bolt keeps breaking

Hi Everyone Happy Independence Day!

This is the second time, the very first bolt (closest to the Rad) has broken off. Didn't try to remove it either time. The first was fixed by Ford under extended warranty. They had to pull the motor and I would think there are easier ways.

I have thought of drilling the bolt and using an easy out. To do this I will have to remove the ac compressor. The bolt is broken off almost right at the block. Before I stared I wanted to check here to see if anyone else has had this issue and to figure out what causes it and fix the issue. After searching I didn't find any threads on this...appreciate any help!

How well and how long did you try to soak with penetrating oil? Did you try tightening the bolts slightly before removing them?
These two things can have a big effect on the desired out come. Those are grade 8 or better bolts. They exist in the hottest part of the engine and go through heat and cool cycles continuously. They have some other heavy stress' placed on them also.

I'm not a machinist, but I've heard it said that the only thing worse than removing a broken off exhaust bolt is removing an broken off exhaust bolt with a broken off easy out in it. If the exhaust bolt broke off when removal was attempted and it's made out of really good stuff, does it make sense that and easy out is going to survive and be successful? Others may disagree, but I'd say pull the head and take it to somebody that know what they are doing. Good luck.

Thanks for the response. I didn't spray it with penetrating oil. I wasn't trying to remove the bolt - it just broke off. It is the second time this has happened, last time was about over 15 years ago.

The Car only has 59 k miles. Really do not want to take the head off. When Ford did it before they raised the motor out of the engine bay. I went to an auto recycler and removed two bolts from a 2.3 in a Mustang. Not Turbo, but the bolts came out easy.

I hear you regarding the easy out - I'm wasn't trying to remove it and the bolt is 15 plus years old, which as you say has gone through many heat cycles. The easy out is brand new and hope it will turn out as easy as the ones in the 2.3 Mustang did.

I have never heard of them just breaking off. That's why I assumed you were trying to remove them.

is the exhaust leaking? i wonder if the manifold is warped, pulling on the last bolt.

-J0N

If you have access to a welder, I'd weld a nut on to the remaining bolt and try to turn it out.

I do not think its warped, with the miles on her and she is stock, just larger exhaust and K&N filter. Not even a boost valve.
I can't weld anything as I can put a bolt half way in. I think it is broken off right at the block or just outside it.
I will post some pics shortly.
Thanks guys really appreciate the responses.

yes it leaks at that corner

Here are pics, anyone know where or what type of pipe is best for the heater core? The pipe I speak of is in the pics below and I need to replace it. The heater core is gone and being a summer baby, I just by passed it with a plastic flush connector and would like to use permanent pipe.

Some people have built the heater piping from copper plumbing tubing. Isolate as best you can from vibration.