My flex piped broke and I've got a replacement. It was broken when I hit a pothole on the interstate. Unfortunately, the outlet of the exhaust manifold has a bend in it on one of the tabs where the stud goes through. I have to either find a way to make the outlet flat again so that the gasket will seal or replace the whole manifold.
One issue is that the car spent it's early life in the northeast and getting the damn pins out to replace the flax pipe was a holy terror due to the salt and one had to be bored out.
If I decide to replace the whole manifold, what am in for when trying to remove the manifold bolts?
If I try to make the outlet surface flat again, is that possible and does anyone have advice on this?

2010 HHR 2.2L

 

That is surprising. Cast iron is pretty brittle, it should crack before it bends.

 

The manifold nuts are fairly loose, 124 lb INCH, the stud is 89 lb INCH, lots of solvent overnight should do the trick.

Junk yard manifolds are cheap be sure to get an identical one. The exhaust gasket costs about the same. Cast iron doesn't likes to be beat on, it probably cracked.

 

RockAuto has new manifolds and gaskets

https://www.rockauto.com/en/catalog/...+manifold,5860

I’ve still got a spare in the parts pile , I bought it off Donbrew several years ago , PM me if you need it.

 

Sturgell, Not sure if you are near Charlotte or Winston-Salem, the Charlotte Pull-a-Part has two 2010s that showed up on the lot Feb 25 & 26. Winston-Salem has one 2010 got there in Late January. Looks like about $26.+ your labor.