Best way to fix stripped 22re exhaust manifold bolt holes
 

Aloha guys. I've been slowly fixing up my 94 4x4 22re T4R. I actually did the whole back end of the exhaust already; new cat, flowmaster 40, new pipe etc. because it was rusted out, but didn't realize my stock manifold was rusted out too. I found that out later when I went to replace the exhaust manifold gasket because I could hear, and smell, a leak from that area. Well turns out the manifold is rusted out on the bottom so no gasket was going to fix that. At the time I needed the truck together to use the next day (it's my daily) so I just installed the gasket and bolted it up. Torqued to spec, but one of the bolts never got to torque spec. I suspect it stripped in the block. That brings me to what I need help with!

I know I can get a kit to fix a stripped bolt hole on the block. I can't remember what they're called, but I've seen them used. I believe you drill it out, tap it the size bigger or whatever the insert calls for, put the insert in that thread match's stock bolt threads and install as normal.

I'm just hoping someone can help me with what size kit I need so I can but that at the same time when I get the manifold.

I would love to get an upgraded header but the cost difference, 600 shipped to 110 and the fact that it's a pretty tired 22re doesn't make sense to me. It's a daily and a beach/surf truck so I just want it reliable. I'm sure just the stock manifold being sealed up properly will make it feel a little more peppy and I won't have to smell the leak or listen to the extra engine noise in the cab.

Anyway thanks in advance! I'm guessing whatever the stock manifold bolts are would be the size kit I need? Going to do some more research.

Helicoil thread repair kit.

You're on the right path with those repair kits. They're typically called helicoil or thread repair kits. You've got the process down: drill, tap, insert. For the size, it's probably the same as your stock manifold bolts. It wouldn't hurt to double-check and maybe measure the remaining good bolts just to be sure.

I replaced a couple of mine with a Heli-coil kit. Doable with the engine in, but I'd recommend getting some stubby bits and a right-angle drill to do the job. Plus, it's really hard to stay centered. One trick is to make an alignment collar you can put into the hole in the exhaust manifold that keeps the bit in the middle.

I hope it turns out well!

You can use a Heli-coil or a time sert.

Another pro tip: Drill the old stud out with a left-handed drill bit. It gives you a greater chance of the old stud backing out.