GM 6.6L Duramax Diesel Exhaust Manifold Broken Bolt Repair Kit - Alberto

What is the GM 6.6L DURAMAX DIESEL Exhaust Manifold Repair Kit?

The GM 6.6L DURAMAX DIESEL 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 GM 6.6L DURAMAX DIESEL Broken Bolt Repair Kit work?

Like all ProMAXX Tool broken bolt repair kits, the GM 6.6L DURAMAX DIESEL 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 GM 6.6L DURAMAX DIESEL Stud Repair Kit

The steps to use the GM 6.6L DURAMAX DIESEL 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 GM 6.6L DURAMAX DIESEL Key Success Drivers

• Fastest — ProKit Plus version includes 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
• Bolts to either top or bottom for ultimate versatility and accuracy
• Can reduce repair times from 3-4 hours to under 40 minutes
• Increase service ledger profitability
• Patented and Made in U.S.A.

Part Numbers: PMXT300PRO, PMXT300, T300, T300PRO, PMXT300APRO, PMXT300A, T300A, T300APRO

Duramax Diesel Kit User Info

Alberto - Exhaust Manifold Repair

• Mount the ProPlate™ to the cylinder head using the included ProFast PPF010625-125 or PPF010625-150 precision fasteners according to the included cylinder head schematic. Torque to a minimum of 20 FT-LBS.
• Insert the ProBushing™ and corresponding ProDrill™ machine grade tooling bit into an air-powered angled style drill and use the drill depth gauge machined into the ProPlate™ to set the proper depth of the bit and mark the bit if necessary. Apply one drop of the ProLube™ PPL001 drilling & tapping cutting fluid. AVOID PENETRATING OIL/SPRAY OR OTHER LUBRICANTS.
• Insert the mounted ProDrill™ into the included ProBushing™ mounted in the ProPlate™ first by slowly and manually turning the chuck until the ProDrill™ slips into the bushing and contacts the surface of the damaged stud. This will ensure the cutting edge is not damaged. Important step to avoid drill bit breakage. While applying light pressure, activate your drill both on and off five times (ten times if utilizing an air ratchet) in one-second intervals. This is the MOST CRITICAL step of this repair as it facilitates precise alignment by creating 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 of the bit providing for cutting extremely hard surfaces and extending cutting tool life.
• After this initial start, drill continuously running your drill at the proper RPM (see below) and while the bit is turning, extract the bit in and out of the damaged stud while maintaining it in the bushing to “clean” or “excavate” cutting debris from the stud. Repeat this step progressively exerting more pressure until your drill reaches the maximum depth.

Begin the Extractorless™ Repair: Using the larger ProDrill™ and the corresponding ProBushing, drill continuously, regularly excavating chips and debris from the drill flutes. Repeat this step with your remaining drill steps. Clear all debris, insert the largest ProBushing™ and attach your tap holder to the ProTap™ PPT010125. Apply two drops of ProMAXX® ProLube™ to the tap. Insert the ProTap™ PPT010150 into the bushing, slowly and carefully turning the tap by hand first clockwise ¼ turn, then counterclockwise ¼ turn, blow down the flutes of the tap to clean debris frequently and repeat this process until the tap stops cutting.

You may also contact technical support at 724-941-0941 for recommendations and procedures.

NOTE. Approximate tooling cutting speeds (Under load): MIN: SSSC125@500 RPM, SSSC188/PLT188@300 RPM, SSSC270/ PLT270@250 RPM and SSSC340@250 RPM.

NOTE: Some air ratchets may not generate at 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.

Alberto User Guide PDF