Had a person show me a '99 Z71 that had an exhaust leak (not a modified truck) two of the exhaust bolts heads poped off, GM won't warranty them. The problem for the dude is one of the bolts was the drivers side rear bolt and fell off clean to the head. He freaked out when I told him the head has to come off. But has this been common to anyone elses truck, just a convience it happend to the hardest bolt to get at, but this guy is an A-hole so maybe he deserved it.

 

My brother's '99 6.0 is on it's second exhaust leak in the past year. The first was a small crack in the passenger side manifold. While Mr. Goodwrench was replacing it, he stripped out a bolt hole on the head, so he put on a new head too. It was fixed under my brother's extended warranty. The repair bill was like $1800.

We're not sure what the new leak is, it doesn't sound major, just a small tick when you go WOT. I need to take a look at it. Maybe it's time for him to get some longtubes.

 

I have seen guys get quote prices to remove the head to repair a broken bolt.I have been able to remove the inner fender and have plenty of room to work

 

Just put som JB on it, it will be fine!

 

I think it must be a relatively common thing. My dad's '99 has two broken bolts but, there is no leak so he's not worried about it. I think it was the rear bolt on both sides but, I can't remember exactly.

 

what would cause the BACK bolts to be the ones with troubles?

 

I don't have a clue what would cause that.

 

I dunno, but when I did my headers that drivers rear exhaust bolt felt weird to get out like the threads were getting smashed against the flange. The reason I could not repair the broken bolts gonzo, one of them I used a stud remover but the back one is impossible even to a right angle drill. Can't remember if the brake booster was in my way but the firewall bulges in front of it I remember that.

 

Your right,you cant get them all that way.Seen several guy pull heads on S10s that didnt need to. Seen guys sell customers on needing a new 1 piece rear main seal when it only needed a oil filter adapter o-ring and gasket.

 

My guess is the bolt was a factory defect or was over torqued at the factory. The exhaust is held in place by 8 bolts so IF the other 7 are still tight the manifold couldn't move enough to cause the bolt to be sheared off. Best to install some header and fasten them down with Stage 8. If you had done that you wouldn't be asking this question. I don't think it's possible to properly drill out a broken bolt with the head installed even with a right-angle drill chuck unless your name is David Copperfield.