exhaust manifold stud broke

[Bub]

recently i had a clutched installed, when i took off the heat shiled, i noticed the exhust manifold, theni saw this stud with the bolt still on, but just lying there on top of the manifold, when i looked inside of the whole where the stud was supposed to be i noticed a peice was still in held by the threds,
Possible dangers? leaks? gaskget is still in place, and so is the manifold, what to do?

 

[Eclipsed]

Originally posted by Bub
recently i had a clutched installed, when i took off the heat shiled, i noticed the exhust manifold, theni saw this stud with the bolt still on, but just lying there on top of the manifold, when i looked inside of the whole where the stud was supposed to be i noticed a peice was still in held by the threds,
Possible dangers? leaks? gaskget is still in place, and so is the manifold, what to do?

Are you talking about a bolt the goes directly into the head or into the turbo?

To tap a bolt out like that, all you need to do is take a small drill bit and drill in the middle of it and then slowly increase the size to the size of a bolt tapper. Get a bolt tapper that you can find at any autoparts store or hardware store. The bolt will come right out. I had this same problem with my exhaust install and cracked a bolt in the 02 housing. It was a pain, but I got it out. Good luck.

 

[Defiant]

If it _isn't_ leaking, it may take it a very long time to get around to it. After all, you don't know how long it's been like this, do you? I'd keep in mind that it needs to be fixed, and then get around to doing it. Fairly soon.

Brad Bauer had a really good article on pulling studs, but his site went down last week.

You might do a Google search for tips.

 

[Bub]

thanks, its the bolt from the exhaust manifold to the head, do you happen to know the size of the bolt, so i can get the rigth tap?

 

[Eclipsed]

Originally posted by Bub
thanks, its the bolt from the exhaust manifold to the head, do you happen to know the size of the bolt, so i can get the rigth tap?

Im not really sure, but arent they like 12 mm? I dont really remember, its been a while since I did those bolts. Just find the size with a socket and then go into a hardware/autoparts store and ask them what size is best to use. You might want to try taking the whole manifold off. If one bolt cracked, I'm sure the rest will. Replace them with all new bolts. Just do the rest now, because in case you snap a few more you'll be ready to tap it out because you got the right tools.

 

[Tallen]

Start simple bub. Get a sharp quality punch. Hammer the punch lightly into the broken stud, but offset to the side. Now using the indentation you made, LIGHTLY hammer the punch in a counterclockwise direction. This will often work. \

Try the easy outs next, but remember they are carbon steel. They are not imerveous to breaking. If you think you are pushing it too far, stop. Heat the stud up and try again. Drill a bigger hole to get more traction. If it breaks....buy a $20 carbide drill bit and cuss at yourself for being stupid.

I do not use them at all for this reason. I prefer to start with a small drill bit (us your punch to make a ncie hole in the MIDDLE of the stud. Then drill straight and level through the stud. Next use a slightly larger bit, then another. Soon you can pluck threads out of the hole with no damage, or just use the punch method to easily tap it out. The big home in the middle of a stud really weakens it. Often the drilling rattles it loose when you ar using a larger bit.

Don't be afraid to weld a nut on the end of the stud. The head is aluminum afterall. It'll live.

 

[jmc94gsx]

I have heard of people totally screwing up attempting to fix this, drilling too deep or at an angle making additional problems, so depending on your own mechanical abilities use caution or don't try it at all. It's something that has a easy explanation, but more difficult than it seems and is made more difficult when it is on the car.

 

[BitAddict]

Added Thought: I had this same problem with two bolts. Traditional Easy Outs wouldnt work, but i used a "Screw Remover" set from sears(cost about 12 bucks) and it worked great! Good Luck