As I have said before, the exhaust manifold on the “new” engine was cracked, so I needed to pull it and swap the good manifold from the old engine. Ford sixes are notorious both for cracked manifolds and for the bolts rust-welding themselves to the head. A fun combination. So in the days leading up I sprayed the bolts with PB Blaster and Freeze Off. Once I started in I used a bolt extractor to get a grip on the badly rusted heads.
End result was six bolts actually coming loose, four snapped off bolt heads and one bolt who’s head stripped badly without shifting. I spent the next while trying to shift the stubborn bolt, I tried the bolt extractor, vise-grips, welding a nut onto the head and probably a half-dozen other things without the slightest sign of movement.
I finally gave up and cut the head off with an angle grinder, and pried the manifold off in pieces. The places it snapped in the pic are not where the cracks were, but just the result of overly enthusiastic prying. Fortunately I didn’t need this piece anymore. Frustratingly, the bolt that had given me so much hassle and wasted so much time, once the manifold was off it came out in moments with a pair of vise-grips.
Once the manifold was off I still had the problem of the four bolts that had snapped off. I was lucky in that they hadn’t snapped off flush, but I still couldn’t budget them. Vise grips would just chew them up, and attempts to heat or freeze them didn’t do a thing. I even tried welding a nut to them and putting a wrench on it. All I did was snap the nut back off.
Finally I gave in and decided that if the bolt wanted to be a permanent part of the head, I would take advantage of that instead of fighting it. So I cut the bolt back about half way with an angle grinder to get a flat surface. Next I cut the heads off some short bolts and chamfered the ends to give my weld someplace to bite.
Then one by one I welded the new bolts to the old once, effectively creating a stud I could put a washer & nut on. Because I was working down in the engine bay I had no good way to get the pieces aligned perfectly straight. So after welding each one I had to grind the welds down and test fit the manifold. I was lucky in that they all ended up straight enough to allow the manifold to slide on and off easily.