Unfortunately these bolts apparently are discontinued, so I can't get them from a dealer. I'm going to try to find someone local who has some extras lying around. Once I get a new bolt I'm going to borrow a power drill and use an easy-out to get this one out, rather than removing the entire intake again.

Yeah, I know now I have to go to 35. It was the "do it once in in-lbs then once in ft-lbs" that messed me up.

 

3/8-16x1.38 or new here Search the RMS Automotive Products Database

 

Maybe a little late, but Oreilly's does carry thread chasers. It's in the loan-a-tools. It's called a thread restorer set. Im an Oreilly employee btw. Might help ya out in future endeavors.

 

So I removed the intake manifold yet again today so I could remove the rest of that bolt. Destroyed my brand new gaskets in the process. A friend and I spent about an hour scraping what was left off of the manifold and the heads. I grabbed a vise-grip to try to get the broken bolt out, and no dice. There isn't enough for me to actually grip onto. I tried to drill a hole for an easy-out before I took the manifold out, but I couldn't get it decent then either.

I'm really at an odds for what to do next....I'm at the point that I'm so frustrated that I'm having a hard time getting the will power to work on the thing anymore. I legitimately wonder if it's even worth it...I feel like I need to hide the thing somewhere until I start craving it again. I've just gotten so sick of it now. I want it to just be done so I can enjoy it, but I don't even know if I can enjoy it anymore.

 

Take a center punch, and grind it to a sharp point, if it isn't already. Hold the point off center, to the left side if the bolt. Give it a couple of whacks straight in with a hammer to make a dimple. Then hold the punch at an upward angle and hit it again with the hammer with some sharp raps. What you're trying to do is spin the bolt out with some impact. It works, but not always.

 

I did try using a center punch to dimple the center of the bolt so I could get it with a drill bit...all that accomplished was flattening the punch. I also don't have any access to a grinder.

The bolt in question is on the driver's side all the way to the front. Could I take my chances with not bolting it down there, or am I about 200% guaranteed that it will leak right away?

 

Probably won't leak until the corner of the intake manifold decides to warp.

 

hmm...didn't think of warpage...

 

So I've tried pretty much everything I can think of, and I still haven't been able to get that stupid bolt out. I really don't know what else to do. I think I'm just going to put the intake manifold back on and call it good enough.

 

Do us a favor and post pics of what it looks like as of right now. Maybe we can help more if we had a visual. As clear as possible, and maybe at a couple different angles, if you can