Exhaust manifold cracked, possibly busted studs. Need some advice...

[L0G1C]

So I'm doing maintenance on my car this last weekend and noticed some exhaust coming from underneath the heat shield. So I pull that off and what do I see but loose bolts on the O2 housing and a huge crack in the manifold! Not only that, but it looks like the studs on the ends are broken, but I can't say for sure since they're still in the head. My question is this: How can I fix those busted studs? I've got a 2g exhaust manifold on order, so I can fix those studs at the same time, but I just don't know how.

Also, what gaskets am I going to need to do this replacement. I know that I need an exhaust manifold gasket, but do I need a turbo gasket or any other gaskets?

 

[AWDJDMTALON]

To get the 2 end bolts out that are broken, you will have to drill the center of the botl out and use and EZ OUT to get it out. It is really sinple and can be doen in the car w/ patience. As for gaskets. Of course the manifold gasket, and now would be a great time to upgrade the maifold to turbo gasket w/ a steel one from some one like Slowboy Racing.

 

[CrazyNikko]

i would soak them in ATF fluid or PB rust pen. for a few days. If you can reach the try to take them out with vice grips or something similar. If you can reach them, soak them then drill. By the way, if they're cracked, your going to need some GOOD drill bits. Titanium, carbide.,

 

[L0G1C]

Awesome. I've got my new exhaust manifold coming out of a 95 GSX, I've already got a new exhaust manifold to head gasket, and I'm shopping for a new turbo to manifold gasket right now.

So, if they are just loose and not busted or cracked, do you think it would be safe to reuse them? I guess I won't know until I actually get the old manifold off. Anyway, I'll be sure to soak them for a few days before hand.

Out of curiosity, how much of a gain will a 2G exhaust manifold give me? Will it be noticable?

Thanks!

 

[Ludachris]

Awesome. I've got my new exhaust manifold coming out of a 95 GSX, I've already got a new exhaust manifold to head gasket, and I'm shopping for a new turbo to manifold gasket right now.

So, if they are just loose and not busted or cracked, do you think it would be safe to reuse them? I guess I won't know until I actually get the old manifold off. Anyway, I'll be sure to soak them for a few days before hand.

Out of curiosity, how much of a gain will a 2G exhaust manifold give me? Will it be noticable?

Thanks!

Do NOT re-use the old mani studs. Go for some SS studs from SSstuds.com. Be sure you drill them straight and centered when removing the broken studs, and be sure you drill the hole pretty big before using the easy-out.

You shouldn't feel any noticable gain with the new manifold, even if it's ported. You still have the small turbine housing that's restricting you, and probably your O2 housing.

 

[L0G1C]

Looking at the studs on SSStuds.com, it looks as if they screw into the head. I thought they were pressed into the head for some reason. I'm going to order all new studs for sure, but I'm not quite clear on how to get them out, though.

 

[slow_talon]

I bought sowboy's racing ported manifold its great i also bought a 4 layer gasket and all the bolts let me tell you its one of the best manifold to buy my turbo spools super fast, definately thumbs up. i would tell you to buy it

 

[BOBS90TURBO]

Hey, I can tell you from a lot of experience in removing broken mani studs.

1. After you drill out the center of the stud to use the extractor, make sure you drill the hole as large as you can and use the biggest extractor you can fit. Drill it almost to the very edges. If you try to use a small extractor, it will break right when you start backing it out.

2. Use a small CARBIDE(only) dremel bit, the one with the little ball on the tip, and take your time.

3. Use lots of heat, take a small torch and heat the shit out of the broken stud before you try to back it out, and again take your time!!!!!!!!! GOOD LUCK.

 

[steve]

I'll only add that if, once you get the manifold off, you find that the stud broke flush with the manifold and sticks out from the head, try using two thin nuts locked together on the stud to back it out. I was able to do that to the broken ones on my engine and didn't have to risk messing the head up drilling.

Steve

 

[FireyIce01]

To get the 2 end bolts out that are broken, you will have to drill the center of the botl out and use and EZ OUT to get it out. It is really sinple and can be doen in the car w/ patience. As for gaskets. Of course the manifold gasket, and now would be a great time to upgrade the maifold to turbo gasket w/ a steel one from some one like Slowboy Racing.

Simple? Wanna come EZ out my bolts every time I break 'em?

As far as the advice goes, that's exactly what you need to do... make sure you use a good drill bit, and if you can, centerpunch it before you start drilling so you have a precise starting point... As far as it being simple... there's not a lot of complicated steps... it's just a PITA... patience, a little heat, PB or Deep Creep or Tranny fluid all work well as lubricants to loosten the threads... if you can get a bite on the bolt with a vice grip after you drill it, sometimes just relieving that pressure (by drilling) will allow you to twist it out... if you don't know any good swear words, go look 'em up, you'll need 'em.

 

[AWDJDMTALON]

Simple? Wanna come EZ out my bolts every time I break 'em?

Sorry about the "easy" part. I have had to remove several sets over the last 6+ years. I guess I forgot how involved it is if it's the first time.

 

[jason732]

Well, I can verify that I have one sheared-off stud, second from the left on the top row. It's sheared off at the head, so I'm going to have to drill it right?

 

[FireyIce01]

Sorry about the "easy" part. I have had to remove several sets over the last 6+ years. I guess I forgot how involved it is if it's the first time.

:laugh: I know what you mean, I usually break at least 1 bolt every time I work on a car... I still haven't replaced the 6th lugnut and stud on front right side on my truck... but I can't say it's ever gotten "easier" I just know what to do now...

And jason, if you can't get a bite on it and turn it, then you gotta drill it to get an ez-out in there... start with a fairly small bit, centerpunch your stud if it's flat (if you have a grinder and room, you might want to make it flat) and then work your way up... use the biggest bit you can without hitting the threads (don't want to have to helicoil the hoie when you're done) All the info's posted already, but there it is again. Good luck on that, it's not diffuclt work, just a PITA most of the time

 

[L0G1C]

Ok, I got my manifold today, and I have a few questions:
First off they sent me these things with it:
Thingy

Is that the turbo gasket? what is it?

And, the manifold has larger holes (for the M10's on the 2G) on the ends, but my head has all the same size studs in it. Do I have to re-mount M10's on the ends or will I just mount it up with all M8's?

The reason I ask is that I can either buy the stainless steel studs from SSStuds.com, or I can get oem replacement studs from slowboyracing.com. I've been told that the only advantage the stainless studs have is that they resist corrosion better, but the stock ones will hold as well as the stainless ones anyway. So which ones do I get?

Lastly, I got these EZ-Outs from my local parts store:
EZOuts
Are these good enough to do the job if I get the right drill bits?

 

[steve]

Ok, I got my manifold today, and I have a few questions:
First off they sent me these things with it:
Thingy

Is that the turbo gasket? what is it?

And, the manifold has larger holes (for the M10's on the 2G) on the ends, but my head has all the same size studs in it. Do I have to re-mount M10's on the ends or will I just mount it up with all M8's?

That's the seal ring and turbo gasket.

Unless you have to wind up getting the head reworked because of problems getting the studs out you just use the M8 studs on the ends.

Steve

 

[L0G1C]

So I don't need to buy another turbo gasket? I thought the stock ones were felt or some other flimsy matierial. Can I re-use this one?