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Broken header bolt?

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Old Oct 3, 2025 | 07:04 PM
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Default Broken header bolt?

Just discovered the PO of my C5 snapped one of the manifold bolts off. Took them off today to do headers and its of course snapped off flush with the head.

I dont have access to a mig welder (and im not even sure I could get one in there with the heads on the car). Anyone have any ideas or solutions for an in-car fix?
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Old Oct 3, 2025 | 07:18 PM
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Both of the outside drivers ones in my truck have been broken off since I've owned the truck, been over 14 years. Even with the room to get to them and I've tried they didn't want to come out. However, with the factory MLS Gasket there's zero leaks. My plan is to fix it if I ever have to pull the Head off. Until then it's one of those if it's not broke don't fix it. Pun intended given the situation haha. I've got the two bolts for it in the toolbox of my truck so I don't lose them when it comes time to put them in.
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Old Oct 3, 2025 | 08:02 PM
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Originally Posted by the_merv
Both of the outside drivers ones in my truck have been broken off since I've owned the truck, been over 14 years. Even with the room to get to them and I've tried they didn't want to come out. However, with the factory MLS Gasket there's zero leaks. My plan is to fix it if I ever have to pull the Head off. Until then it's one of those if it's not broke don't fix it. Pun intended given the situation haha. I've got the two bolts for it in the toolbox of my truck so I don't lose them when it comes time to put them in.
I was considering that as well. I know theres also kits for brackets that will bolt on to the head and act as a bolt. I was thinking it hasnt leaked so far so as long as the header flanges are flat I hopefully won't have an issue.
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Old Oct 4, 2025 | 09:17 AM
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If you keep burning gaskets then just pull the head or drop the engine out the bottom to get access with a welder
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Old Oct 4, 2025 | 12:19 PM
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Double up the MLS exhaust gaskets. I guarantee it won’t leak even with 2 or 3 broken bolts. The trick with headers is to NOT overtighten the bolts….you’ll bend the header flange and then you’ll have leaks forever. I double up MLS exhaust gaskets even on new builds…with headers it’s a sure way to prevent leaks.
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