Ford Gas 4.6L 5.4L 6.8L Diesel 6.0L 6.4L Exhaust Manifold Broken Bolt Repair Kit - Rocky II

What is the FORD GAS 4.6L, 5.4L, 6.8L, DIESEL 6.0L AND 6.4L Exhaust Manifold Repair Kit?

The FORD GAS 4.6L, 5.4L, 6.8L, DIESEL 6.0L AND 6.4L Exhaust Manifold Broken Bolt Stud Repair Kit, along with every other USA-made ProMAXX Tool solution, greatly reduces repair times, allowing professional vehicle technicians and skilled mechanics to quickly make the fix and move on to other jobs. The kit is easy to use, and it comes with instructions and schematics that show the best ways to mount the guide plate and use the included drill bit tooling to get at every broken bolt on the manifold.

Make the Broken Bolt Repair Fast…ProMAXX Fast!

With a focus on book time saved, return on investment, and increased productivity, experienced technicians and mechanically adept individuals who follow the provided instructions can use these kits to make the fractured stud repair in approximately 15 minutes per bolt. A professional-grade drive ratchet is required to make the repair.

How does the FORD GAS 4.6L, 5.4L, 6.8L, DIESEL 6.0L AND 6.4L Broken Bolt Repair Kit work?

Like all ProMAXX Tool broken bolt repair kits, the FORD GAS 4.6L, 5.4L, 6.8L, DIESEL 6.0L AND 6.4L Engine Exhaust Manifold Broken Bolt Stud Repair Kit stands out for its exclusive screw-in bushings and proprietary mating angles, which ensure perfect alignment of the ProPlate jig with the cylinder head. The ProPlate can be bolted in any position with included precision fasteners, providing unparalleled repeatable and predictable results.

This level of accuracy and precision sets the kit apart from other products on the market, which rely on inexpensive clamps or loose slip-fit bushings. The accuracy allows the user to drill dead-center on the bolt hole.

For previous repair attempts or botched repairs, the ProKit’s larger plate holes provide the use of a thread repair kit that includes bushings, bits, and black-oxide coated threaded inserts to restore the cylinder head to factory condition.

Premium Machine-Shop Grade Drill Bit Tooling Included

ProMAXX Tool’s USA-made machine-shop-grade tooling bits are ground at 135° cutting angle (lip) with a split point. Flat ground bits cut slower and are long lasting but less accurate and will walk while drilling.

Split point ground bits will stay on center to reduce walking because they have four cutting edges and distribute loads better. They work well on curved shapes and alloy and stainless steels because it creates smaller chips to minimize clogging holes and breaking bits.

To prevent drill bit breakage, closely follow the instructions in the Exhaust Manifold Repair Kit User Guide.

How To Remove Broken Exhaust Manifold Bolts Using the FORD GAS 4.6L, 5.4L, 6.8L, DIESEL 6.0L AND 6.4L Stud Repair Kit

The steps to use the FORD GAS 4.6L, 5.4L, 6.8L, DIESEL 6.0L AND 6.4L Repair Kit are detailed in the Exhaust Manifold Repair (EMR) manual. The manual provides a step-by-step guide on how to mount the ProPlate to the cylinder head, how to insert the ProBushing and ProDrill into the ProPlate, how to set the cutting edge, and how to extract the remnant or go Extractorless™ and drill the bolt out entirely. In the case of extraction or tap failure, ProMAXX Tool provides free 24/7 technical support at 724-941-0941.

Exhaust Manifold Bolt FORD GAS 4.6L, 5.4L, 6.8L, DIESEL 6.0L AND 6.4L Key Success Drivers

Key Success Drivers for Ford Engine Repair Kits:

• Fastest — Interchangeable bushings with fasteners and Extractorless™ capability.
• Easiest — Simple to bolt on and make the repair.
• Smallest — Easily fits behind the shock tower.
• Most Precise — Engineered .001” accuracy, .0001” dead flat.
• Versatile — Unique CNC machined thread repair kit available as well.
• Patented and Made in U.S.A.

Rocky II User Guide Info

FORD 4.6L 5.4L 6.8L DIESEL 6.0L 6.4L FIX MANIFOLD STUD - ROCKY II
Exhaust Manifold Repair

Congratulations on your purchase of a ProMAXX® engineered performance device! Our tools have the highest quality and precision in the market delivering the most productive repair. All ProMAXX® tools are manufactured in the United States of America from American materials and craftsmanship. We proudly provide limited lifetime warranties and free unlimited technical support. Need help with the repair? Contact ProMAXX Technical Support @ 724-941-0941

• Mount the ProPlate™ to the cylinder head using the included ProFasteners (PPF008375 or PPF008500) according to the enclosed cylinder head schematic. Torque ProFasteners to a minimum of 20 FT-LBS.
• Insert the ProBushing™ into the ProPlate™. Then insert the corresponding ProDrill™ machine grade tooling bit (included) into an air-powered, angled-style drill. Using the drill depth gauge, machined into the ProPlate™, set the proper depth of the bit and mark if necessary. Apply one drop of ProLube™ (PPL001). AVOID USING PENETRATING OIL/SPRAY OR OTHER LUBRICANTS WHICH ELEVATE CUTTING EDGE TEMPERATURES CAUSING THE BIT TO BURN AND CEASE CUTTING.
• Insert the prepared ProDrill™ into the mounted ProBushing™ by slowly and manually turning the drill chuck until the ProDrill™ slips into the bushing and makes contact with the surface of the damaged stud. (This will ensure the cutting edge is not damaged.) *Repeat this procedure for each sequential step in your application.
• SET THE CUTTING EDGE: Important step to avoid drill bit breakage. While applying light pressure, activate your drill both on and off five times in one-second intervals (ten times if utilizing an air ratchet). This is the MOST CRITICAL step of this repair, creating precise alignment (a seat) for the tooling bit to stay on center and not follow the angular broken surface of the stud. Moreover, this step allows the surface of the stud to conform to the cutting edge of the bit, distributing the load evenly across the entire cutting edge, which is essential for cutting extremely hard surfaces and extending the life of the cutting tool.
• After Step 4, run the drill continuously at proper RPM (see cutting speeds below). While the bit is turning, slightly extract the bit in and out of the damaged stud to “clean” or “excavate” cutting debris from the stud (commonly referred to as peck drilling). Repeat this step progressively, exerting more pressure until the drill reaches the marked depth.
• Inserting ProTractor (PPT125): Remove the ProPlate™ and place the optional ProCutter (PPC007A) in the drill. Insert the protruding portion of the arbor into the drilled hole. Toggle the drill on and off five times to remove the burr and clean the tapped hole. With ProTractor (PPT125), place a mark approximately ¼” from the end and lightly hammer the ProTractor (PPT125) into the remnant, to the ¼” depth line. DO NOT INSERT THE PROTRACTOR ANY FURTHER THAN 1/4" depth line. Place the included slip-nut over the ProTractor™ and slide it up against the cylinder head. While holding the opposite end of the ProTractor™ and using a high-quality calibrated torque wrench, slowly and carefully apply torque, first in the clockwise direction, and then in the counterclockwise direction to loosen the damaged stud. Repeat this motion several times NOT EXCEEDING 75 IN-LBS OF TORQUE FOR THE PPT125 OR 150 IN-LBS FOR THE PPT188. If the damaged stud fails to release, STOP and remove the ProTractor™ and proceed to the next step.
• Inserting ProTractor PPT188): using the larger (optional) ProDrill™ and corresponding ProBushing™, repeat steps 3-5 to prepare in using the larger extractor (PPT118).

NOTE: In the unlikely event an extractor fails or breaks, contact technical support at 724-941-0941 for recommendations and procedures. ProKits can also be upgraded to be an “Extractorless” repair: Repeating drilling instructions above and chasing threads clean with a machine-grade tap.

NOTE: ProMAXX® does not recommend tapered left-handed screw extractors as they have the potential to deform the remnant in the cylinder head increasing complexity of extraction. In addition, these extractors cannot be turned clockwise to unlock the damaged remnant. Approximate tooling cutting speeds (Under load): MIN: SSSC125/PLT125@500 RPM, SSSC188/PLT188@300, SSSC266/270/ PLT270@250.

NOTE: Some air ratchets may not generate sufficient RPM under load to be effective. See ProMAXX® ProRatchet PPR5260 or PowerDrill™ PPD2800 at www.promaxxtool.com for optimum efficiency and maximum productivity.

PROMAXX™ machine grade tooling is specially engineered to close tolerances of (+) .000” and (-) .001” and ground straight to ensure accurate and repeatable results in using your new device. Specify PROMAXX® genuine replacement parts and tooling for optimum performance and extended warranty coverage. Always use appropriate OSHA-approved safety glasses/goggles and protective gloves while using this device and performing this operation.

Rocky II User Guide PDF