Started my header install today - Ford Bronco Forum
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post #1 of 47 (permalink) Old 11-05-2007, 03:56 PM Thread Starter
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Started my header install today

I was going to wait till after christmas to start this project but i just couldnt wait. I went ahead and ordered my bassani y pipe and egr eliminator kit with block off plate for the intake manifold i got my headers in a few days ago. So this morning i got started it went pretty easy i only had one header bolt break off but it snapped off flush with the head. I got the cracked manifold removed and all the egr stuff out of there i did the passenger side first because people told me it was the worst side but it went pretty smooth with the inner fender removed. I guess i will get an easy out and try to get the snapped bolt out of the head tomorrow i have never used one before what can i expect? I did soak the broken bolt with pb blaster so that might help when i try to get it out tomorrow.Here is a pic of my cracked manifold and egr valve that was loose as could be from the manifold and the snapped off manifold bolt.


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post #2 of 47 (permalink) Old 11-05-2007, 05:06 PM
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Hey, I'm getting ready to start a very similar project. Please keep us posted of the progress.

P.S. Good luck getting that bolt out.

88 Bronco XLT 351w C6 auto
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post #3 of 47 (permalink) Old 11-05-2007, 05:11 PM
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I am taking another tack with my swap. Im doing it when I replace the engine.

Paul B

'95 Bronco XLT 5.0L/e40d working on 5.0HO Crane 2030 cam,early 351W heads ported w/194 valves,shorties,Homemade Ypipe,K&N CAI,Flowmaster cat back,procomp 3000 shocks,MM manual hubs
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post #4 of 47 (permalink) Old 11-05-2007, 06:06 PM Thread Starter
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Yeah i am gonna get on that first thing after i go pick up an easy out. I also ordered plugs for the back of the heads so i can remove all this smog stuff hopefully they will be here this week.

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post #5 of 47 (permalink) Old 11-05-2007, 07:11 PM
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removing teh smog equipment?!?!


What headers did you get?
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post #6 of 47 (permalink) Old 11-05-2007, 07:35 PM Thread Starter
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I got the bassani headers.

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post #7 of 47 (permalink) Old 11-05-2007, 09:59 PM
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post #8 of 47 (permalink) Old 11-06-2007, 07:20 AM Thread Starter
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I saw those at lowes but i didnt think they would work.

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post #9 of 47 (permalink) Old 11-06-2007, 09:30 AM
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left hand drill bit if you can fit a drill in there
works like a charm
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post #10 of 47 (permalink) Old 11-06-2007, 02:48 PM Thread Starter
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Well i got the bolt drilled and i used an easyout the header bolt came loose and as i was backing it out the easyout snapped. Now its hard as hell to drill any suggestions on how to drill out the easy out?

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post #11 of 47 (permalink) Old 11-06-2007, 03:42 PM
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DOHHHH!!! Ya, I HATE EZouts!!!!!!!!!!!!!!!!


Last one I busted I ground out with a dimond tip dremel bit.

Paul B

'95 Bronco XLT 5.0L/e40d working on 5.0HO Crane 2030 cam,early 351W heads ported w/194 valves,shorties,Homemade Ypipe,K&N CAI,Flowmaster cat back,procomp 3000 shocks,MM manual hubs
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post #12 of 47 (permalink) Old 11-06-2007, 04:13 PM Thread Starter
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Yeah i am gonna get a carbide drill bit to drill it out. I started pulling the other manifold off i got 2 bolts out so far i hope to have them all out tomorrow i hope i dont have anymore bolts break.

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post #13 of 47 (permalink) Old 11-06-2007, 05:01 PM
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now its time to go buy the left handed drill bit
and have drilling an easy out out
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post #14 of 47 (permalink) Old 11-06-2007, 05:22 PM Thread Starter
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Where can i find a left handed drill bit?

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post #15 of 47 (permalink) Old 11-06-2007, 05:24 PM
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a real hardware store
ive seen them at napa as well
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post #16 of 47 (permalink) Old 11-07-2007, 10:10 AM Thread Starter
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I went all over town and i couldnt find any left handed drill bits but i did order some. I came back home and got to work on the drivers side manifold i broke 2 bolts off in the head luckly one had broken off and left about an inch and a half
of bolt sticking out some pb blasted and my small pipe wrench and she came right out. The other bolt broke flush with the head and its the second one from the front its gonna be hard to drill because of the spring bucket. I cant do much more till i get my new drill bits if they dont work i might just leave a bolt out of each side of the header. My headers have a thick flange and a good gasket if i cant get these bolts out hopefully 7 bolts will stop it from having leaks. I am gonna do my best to get them out i have seen missing header bolts on chevys and not have them leak but as my luck goes it will wanna leak. I got my egr resistor eliminator kit in yesterday i am just waiting on my block off plate for the intake also my bassani y pipe will be here friday
so if all goes well i might have new exhaust on this weekend and go get the muffler and tailpipe installed on monday.

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post #17 of 47 (permalink) Old 11-07-2007, 10:17 AM
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they will leak. Its gona be a pain, but you gotta get them out. Sorry man

Paul B

'95 Bronco XLT 5.0L/e40d working on 5.0HO Crane 2030 cam,early 351W heads ported w/194 valves,shorties,Homemade Ypipe,K&N CAI,Flowmaster cat back,procomp 3000 shocks,MM manual hubs
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post #18 of 47 (permalink) Old 11-07-2007, 11:47 AM Thread Starter
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The one on the passenger side should come out pretty easily cause its easy to get to. The one on the drivers side did break loose before the bolt broke so maybe it wont be to bad. I have been soaking both of them with pb blaster
so we will see what happens.

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post #19 of 47 (permalink) Old 11-07-2007, 02:09 PM Thread Starter
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YEAHHHHHHHHHHHH I went outside to see if i could drill a hole in the center of the drivers side broken header bolt and i got my drill in there but i couldnt get a flat spot. I got my dremel tool and ground a flat spot then i used the dremel tool to drill a hole in it. That worked like a charm i got the hole in there then i used one of those spiral easy outs from craftsman and it came out like a loose tooth.
I am glad it came out easy because it was in a bad spot. I am going to try to get the other one out tomorrow on the passenger side i tried some more but that broken easyout is harder than my head. I stopped working on it cause i was fixing to get a sledge and beat on it.

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post #20 of 47 (permalink) Old 11-07-2007, 02:13 PM
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once you get that left handed one it will be a little but a lot easier.
i used one on my hubs and it was like night and day
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