jeepnut24

While drilling out a broken exhaust manifold bolt, one of the smaller drill bits when all the way through.... This is on a 2002 5.3. Is this something a machine shop could fix, or will I need a new cylinder head?

Rear passenger side was the bolt...

I didn't get much feedback in the other forum, so Im trying here.... I would like to avoid buying another head if I can.

LS1NOVA

iTrader: (12)

It goes into the water jacket, I would think that a little thread sealant on the bolt when going back in would work ok.

jeepnut24

That is my guess, the pilot hole went into a pocket behind the bolt.

If I were to plug the whole, what is a good material to use? Brass? Steel? I was thinking a setscrew with some high temp loctite would work.

Pop N Wood

iTrader: (1)

Aluminum heads can be easily welded. Not familiar with 5.3 motors so excuse me if they are cast iron.

bczee

iTrader: (12)

You could try some JB Weld and thread sealant.. I would think that would be enough

Also.. if aluminum.. you could try one of them Aluminum weld/brazing rods.. I am sure a machine shop should be able put a perment fix in place if you don't want to try any of the suggeted fixes.

pdsq98gt

It is definitely a water jacket behind that bolt hole. Just put pipe thread sealant on the exhaust bolt ant it shouldn't leak. Just beware if you take the bolt out with coolant in the engine, it will run out.

jeepnut24

It going to be a difficult weld because its at the back of the 10mm bolt hole. They are aluminum heads.

Pop N Wood

iTrader: (1)

Take it to a welding place and see what they say. Maybe drill it out bigger, weld the whole thing up flush then drill a new hole.

Of course that solution means pulling the head which means new head bolts.

One last thing to consider. If you helicoil the I assume stripped out threads then I don't think thread sealant will work.

jeepnut24

The old threads are about 93% and I think ok with just a good thread cleaner. I managed to get it out without getting into them too much.

The other alternative is a JY replacement head. I have found them for $100 apiece locally.

Jaysz28

iTrader: (19)

Why not use studs instead of bolts

that way you can seal it up good and not worry about it later on down the road

jeepnut24

I hadn't thought about that, but that is a good idea. Thanks.