Arrrgggg!!!! I'm at my wit's end!!!! I've searched the forum for any references to this, even in car forums but cannot find. . . I've gone to the Hedman Hedder website and there was no help (other than offering to sell more exhaust bolts). Maybe that's my only solution--cut the darn things off and replace them. I'd do that, but if I can't get a wrench back to loosen this LAST bolt, chance is slim that I'd get a Dremmel tool back there either.
My apologies in advance for the length, but a short explanation tends to lead to too many follow-up threads and/or obvious "should have told them that to begin with". . .
The previous owner (or a lousy shop he contracted) of this vehicle put in a set of Hedman Hedders to give them more HP to tow with--made sense. Now that I've torn it down a little bit, someone did a slip-shod job. It seems the gasket between the head and the Hedman Hedder (their spelling) flange was compromised and subsequently BLOWN prematurely by them not torquing the exhaust bolts to specifications. Matter of fact, they didn't even tighten them all the way!!!!
Here's what equipment/parts I have on my hands:
- 1989 F-250 with 5.8L (351 cid) engine with 98K original miles
- Fender "splash bib" removed for better access
- off-the-shelf Hedman Hedders replaced original exhaust manifold ~3 years ago
- Hedders are pre-tapped for stock emissions crap (see picture herein)
--If it matters, Hedman label on hood shows "Model #89421"
--A separate line item lists "Cars ED # D-167-22"
--Yet another line items shows this model fits 1986-1991 models
My issues, questions, hopes, and prayers that someone can give me a clue:
Exhaust/Hedder bolts AND spark plugs are nearly impossible to remove easily:
1. Only 3 of the 8 on the one side I'm working with (pass. side) of the bolts are inaccessible with a socket of ANY kind, open-end 1/8 turn at-a-time (at MOST) with the others
2. All but ONE has now been removed and that one is not viewable in the picture attached (that's PART of problem--it's not viewable at any angle)
3. This last bolt, now partially removed seems to be blocked by the hedder tubing itself
-- that is, it won't come out anymore unless the tubing is also bent to accommodate the xtra 5 threads worth to fully loosen
4. ONE of the spark plugs is all but removable unless the hedder is off!!!!
Any hints on this removal process??? The reverse will be MOST important as well as the original installers obviously didn't do it
as I'll need to get SOME level of torque to these bolts to be consistent--I won't be able to get a torque wrench to many of these.
Bolts for EGR taps (well, I think this is for the EGR. . .) :
1. I need to remove these bolts to fully remove the hedder--to spec the possible warping of the surfaces b4 replacing
2. Thus far I've tried every "proper" tool (tube open-end wrenches), then the old standby (ViseGrips
), but no budging on 3 of the 4
3. I need to stop attempts until a more informed person might have a clue here as they are losing their "corners" from the missed loosening process
This is my son's truck and we're putting it back in shape so he can use it to go back & forth to college, so I need a better job than was done by previous owner.
Sorry for length folks, but most need a good starting point/explanation of the issue. Thanks in advance for any input,
WhoBuB/Jesse
P.S. Remember to see/view the attached picture for the "1,000 word" explanation
'89 F250--Removing "blind" & tight exhaust manifold bolts 
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