Broken Exhaust Stud/Screw Removal [Merged 8-8] bolt fastener threads

[RoasT BeeF]

I have two bolts that are broken off inside the head that bolt the exhaust manifold up. Any ideas for getting them out without messing up the threads? I was going to try drilling them out but I cant even get my drill in there. I am also going to need to take the power steering pump off to get to one of them. Anybody done any of this?

Tech Article:
http://www.dsmtuners.com/forums/art...-broken-exhaust-stud-removal.html#post1489888

 

[92GSXman]

Oh yeah, as for porting your manifold you will be wasting your time with a dremel. You'll need some air tools for sure and a carbide porting bit.

 

[92awddsm]

Another option for a budget is to drill, tap and put a larger bolt in using LOCKTITE. Now grind the bolt off flush with the head. Now you can drill and tap the new surface and install the original size stud. Be carefull not to go too big or too deep.

 

[whitegst97]

Any luck removing the stud out of the head, last time that happened to me in my previous car i have to remove the head and have the stud helicoiled out. Well i need help removing the nut from the stud that's right behind the power steering pump. Any one have pictures of tools i could use to get it out, do i really need to remove the powersteering pump? Notice this is a 1g, lot harder than the 2g. Thanks

 

[JohNneGST]

im sure u have a impact gun of some sort or air ratchet , if so use a torck , heat it up cherry red and zip it off no problem

 

[JohNneGST]

sorry, use a TORCH

 

[whitegst97]

is that in reference to my question? a torch? I need to remove the nut i just need to know how to get to it since there isn't enough space. Thanks

 

[Green93TalonTSi]

Yea I got them out, no biggie. just drilled a pilot whole and used an extractor and it came right out. Now I have another 1, how do u guys remove broken studs from the Turbine housing ? a turbo bolt and an o2 housing bolt both broke off in the Turbine housing, do i need to heat it up and then use an extractor or what ? tell me how u guys get them out.

 

[TalonJohn94]

Do you think that stud like to break because we (I) forget to re-install that bracket that bolts up right there, and that stud is a little longer or something?

The bracket for engine removal that is?

I just had the same stud break on me.

:thumbdown

 

[nuggets]

Exhaust work sucks! I just took mine off yesterday breaking many bolts. On off my bolts for my o2 housing to downpipe broke but there is plent of thread sticking out that I might be able to just through a nut on there. Let me know if this is a bad idea....

 

[MrDee]

It is always a great idea to create as much clearence as possible when workin on exaust manifold..removin fans takes only seconds...that way you tools get to hold and work just as they were made to...also dude..pacience is unreplaceble...after breakin something..it is best to leave the car alone for some time and go curse and cool off..you be amazed how many ideas you have when you come back....also BE SPRAYING SOME DEEP CREEP EVERYTIME YOU PASS BY THE CAR

 

[canucatchdis]

I am about to put a 2g exhaust manifold on my 1g turbo and i have 150,000 miles. Has anyone else installed one with around that many miles? What i am worried about is that the studs and bolts are so old that the studs may bust as I try to take them off. What are your guys experinces?

 

[Endz0r]

i broke one of the bolts that goes from the manifold to the turbo...if i were u, i would get as many new parts as you can, and to wd40/liquid wrench/whatever the hell out of those badboys.

 

[jott5555]

the nigh before you start your project just soak the studs down wery well.. several time within like 1 hr incriments.. then when you remove the mani remove and replace the studs with new ones. any autp parts store should have them and go with 13mm nuts on the studs so they have better strength next time

replace the gasket between the mani and the head. replace the gasket and bolts from the mani to the turbo and when in there you may as well do your o2 gasket, 3 bolts and 1 nut.

that way you know they are all good.. and have a helicoil kit and drill on hand so if you do break one you can drill it out and then helicoil it.

 

[Turblown]

Not to jack the thread or anything... but who's got the best Manifold Bolts/Studs? Is everyone just getting them from the dealer or autoparts store? I'm looking to replace the whole set for Intake and Exhaust. I know ARP has the best Head studs... but what about the manifolds?

 

[canucatchdis]

well there is ssstuds.com And stainless is supposed to be great stuff. And i think it is only 30 bucks. I think it is only for the exhaust mainfold to the head though.

 

[Generation1JeY]

kinda off topic, but does anyone have a good way to tighten the nut on the bottom right of the manifold to the head? It is so tight on my car i cant even tighten it so its just a nut half way threaded not even doing its job. I want to take a picture of it, but i'm sure a lot of people know which one i'm talking about. Theres like just enough room to see it but no tool i have can fit in there to tighten it....

back on topic, any bolts u take out, make sure to just replace them with stainles steel ones and coat them good with some anti sieze. U will thank urself later along the line for doing this incase u ever have to take it off again. I had a hell of a time putting on my 3" o2 eliminator and 2g manifold.

The anti sieze wil smoke a lot when u start the engine at first, but just be aware its not an exhaust leak its just the anti sieze burning

 

[mxpimp18]

I just put a new manifold on my 1g with 155k. Four studs broke, was able to get 2 of them out. My head needed rebuilt so I just had the head place take the other two out. And I was soaking the nuts a week before.

 

[jott5555]

to get at that one little last drivers side bottom bolt i use a pivoting extention. it works pretty well..

 

[Tx97GSX]

I just recently installed my 20g and broke 2 exhaust manifold to turbo bolts. So now I'm running with just 2. I'm going to buying a new Turbine Housing and using a shit load of Anti-seize so it doesn't happen again.

 

[oldman]

Hey guys, I have a broken manifold stud. It's about half an inch inside the head. I tried to remove it using a Black&Decker #3 extraction screw and the tip broke off. . Any good ideas? Thanks.

 

[blackGSX2g]

I used a chisel..hammered a good screwdriver pattern into it and it twisted right out. If you can't get it out yourself, a machine shop should be able to get it out for pretty cheap.

 

[oldman]

I used a chisel..hammered a good screwdriver pattern into it and it twisted right out. If you can't get it out yourself, a machine shop should be able to get it out for pretty cheap.

You think a chisel would cut throught it? Colbalt bits didn't even make a dent. I will try the chisel idea tomorrow. I've already call local machine shops and they all want me to bring the head to them. Thanks.

 

[Spoolin98]

MachV has an article about this on there site. Check it out, may come in useful.
http://www.machv.com/tip10manrep.html

 

[oldman]

Thanks for the link but my problem is getting throught that extraction screw tip in the middle of the broken stud.

 

[v8s_are_slow]

i'd think the cobalt bits would go thru it. did you center punch it? maybe try a prick punch (would be a smaller dent). using a really small drill bit? and drilling really slowly? if you drill too fast, the bit isn't gonna cut into it (and if the drill is just one speed and can't go slow, don't waste your time. it has to go slow). if you can start drilling into it, keep drilling until the bit goes all the way thru (making sure to keep it centered). you'll feel it give way once it goes thru the bolt. may take some time of course. but drilling all the way thru will take pressure off the bolt. which if you didn't do that already, that's probably why the extractor wasn't backing it out and broke off instead. imagine taking a bucket of sand and then sticking your foot in it, it'll just push the sides of the bucket out and create more pressure on the sides. same thing. anyway, if you can drill all the way thru it, then move up to the next size bit until another extractor fits in there comfortably. anyway, good luck.

scott