Header bolts - chances that they break when removing?
Thread Starter
Joined: Nov 2001
Posts: 816
Likes: 2
From: Lake Delton, WI
Header bolts - chances that they break when removing? It's been awhile since I posted! Back in summer of '02 (car had almost 30K on it) I had some Hooker LT headers installed. Fast forward to today. I'm going to be removing the Hooker system and installing a stainless ARH system. I'm just worried the header bolts may break, which would REALLY suck! The car now has ~65K on it and it has seen rain only once and never been in the snow/salt. I'm hoping that even though it's been 23 years since those bolts have been out, the relatively low miles on them (~35K) and pristine driving conditions will help with removing those bolts. They are still the OEM bolts.
So, anyone recently removed those bolts for the second time years later? If so, how did it go?
So, anyone recently removed those bolts for the second time years later? If so, how did it go?
Last edited by JR HAWK 9; Aug 20, 2025 at 10:53 AM.
Thread Starter
Joined: Nov 2001
Posts: 816
Likes: 2
From: Lake Delton, WI
Yep, plan on spraying them a few times a day for a few days with Kroil.
I also will be buying a cheap 110V wire feed welder to have just in case I have to go that route if one breaks. It's been 35 years since I welded, but it doesn't take a master welder to tack a washer/nut on the end of a stud. LOL
I also will be buying a cheap 110V wire feed welder to have just in case I have to go that route if one breaks. It's been 35 years since I welded, but it doesn't take a master welder to tack a washer/nut on the end of a stud. LOL
Thread Starter
Joined: Nov 2001
Posts: 816
Likes: 2
From: Lake Delton, WI
I guess I just am curious if any of you have recently successfully removed -all- of the header bolts w/o any of them breaking?
I'll be doing this if any of them break, granted, it won't be as easy with the heads still in the car, but should still be doable.
I'll be doing this if any of them break, granted, it won't be as easy with the heads still in the car, but should still be doable.
i just removed the original header bolts from my 99 Z with 107k back in may without any issues. Car has never seen snow or salt and it was originally from NC. I would say as long as the heads, headers and bolts arent heavily corroded which by the sounds of it they arent then you should be in good shape. If you have trouble getting any of them loose id recommend stopping and using penetrating fluid.
Thread Starter
Joined: Nov 2001
Posts: 816
Likes: 2
From: Lake Delton, WI
i just removed the original header bolts from my 99 Z with 107k back in may without any issues. Car has never seen snow or salt and it was originally from NC. I would say as long as the heads, headers and bolts arent heavily corroded which by the sounds of it they arent then you should be in good shape. If you have trouble getting any of them loose id recommend stopping and using penetrating fluid.
Here's another video I found. just documenting it in my own thread in case I need it later.
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Thread Starter
Joined: Nov 2001
Posts: 816
Likes: 2
From: Lake Delton, WI
Correct. Garage kept it's whole life and maybe seen rain twice many years ago in the early 2000's. I have rinsed the engine bay down with Simple Green a handful of times over the years though. The bolt heads have some surface rust on them, but nothing major at all.
I just talked to a buddy with a '99 SS with almost 200K on it. He just removed his OEM manifolds for the first time 3 years ago and he had zero issues. I guess there is some hope I won't have to break out a welder!
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ive never broken one even on rusty pos truck engines, soak them in your favorite penetrant for a few days and only use a ratchet to break them free and have patience, if one starts turning too hard, turn it in and out with more penetrating oil until it frees up
TECH Apprentice
Joined: Jun 2004
Posts: 318
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From: Charleston, SC
I soaked mine with PB Blaster for a couple days….I’d rather spend $3 and improve my odds for success. If you spray them down, just put some cardboard under your car to protect your floor.
Teching In
Joined: Jul 2018
Posts: 14
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From: Tumwater WA
I know that this is going to sound wrong, but if you can get at them with a 3/8 impact wrench, spray them with PB and get after them with the impact. When ever possible that is what I do. Hundreds of exhaust manifolds over the years. Only ones that ever broke were the ones that I had to use a ratchet on.
Teching In
Joined: Aug 2025
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This doesn't help you right now, but when you go to reinstall them, apply some nickel-based anti-seize compound to the threads.
Copper base is best for high temp, but you'll get galvanic corrosion occuring with the aluminum heads
Copper base is best for high temp, but you'll get galvanic corrosion occuring with the aluminum heads
TECH Addict
Joined: Dec 2017
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I just am curious if any of you have recently successfully removed -all- of the header bolts w/o any of them breaking?
I use stainless steel bolts and put plenty of anti-seize on them. I use the aluminum kind for that. If you used regular steel bolts and no anti-seize when you installed them, you might not be lucky this time though. As said, soak em good with penetrating oil (NOT WD-40), it'll improve the odds.
