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exhaust manifold studs broke

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636chris

10+ Year Contributor
153
0
Aug 15, 2009
philadelphia, Pennsylvania
whats up guys. ill make a long story short i just got another talon with the motor and trans pulled ,so last night i was cleaning the engine to get ready to put a new head gasket and arp's in before it goes in the car(preventative maintenance) and i noticed two stud holes are tapped out slightly bigger and one still has a stud broken off in it .

so what are my options (cheapest possible) . can i just drill and tap for a slightly bigger size, or drill it out and helicoil the holes . im stuck in a sh*tty situation right now and i really don't have the time or money to get another head or take it to a machine shop but its rather be safe than sorry , im worried i might have to get another head and i doubt anyone would buy this one for around the same going price around here
 
yeah its broke off flush. so you saying i possibly have a seven bolt head? i know the bottom end its a 6 bolts how would i check the head?
 
Use a 21/64" drill bit, then helicoil it with m8x1.25. Then you'll be set
 
yeah its broke off flush. so you saying i possibly have a seven bolt head? i know the bottom end its a 6 bolts how would i check the head?

It was a generalization I made. Might not be accurate since I just checked two motors I have in the garage and one is definitely a 6 bolt and has nine 8mm studs. The other motor I just pulled out has seven 8mm studs and two larger ones. It also is a 6 bolt motor from what I know but I have yet to pull the trans to confirm it.
 
mines definalty all six bolt i think where gonna tap out the screwed up holes for a bigger size thread . more work than i wanted on top of hunting down the trans bolts and everything else to putthe motor trans and t case back in
 
Where are the two larger stud holes located?
 
One is located on the lower left hand side ( if your standing in front of the engine). The others ill have to look when I get home from class.
 
I would just drill it out and heli-coil it back to stock size, I've done it numerous times without issue. No matter what you do, be absolutely certain you don't drill too deep and go through a water jacket or something worse. An easy way is to just take some tape and mark your drill bit at the depth you want.
 
Thanks for the quick replys . Ill have at it this weekend . I'm still waiting on a head gasket and timing Belt ,so ill do it when the head comes off(not to mention I gotta figure out where bolts go to put te motor and trans in) wish me luck 50 Degrees this weekend
 
If you have, or have access to a welder I would try the nut trick. Take a nut of similar size to the stud. Press the nut to the head with a pair of pliers and zap a good bead in there. Let it cool a little and work it back and forth slowly.
 
That sounds a lil skechy to me man LOL thanks for the suggestion tho
 
What do u mean 30 3/8 nuts and six sticks LOL
 
I put the 3/8 nut on top the broken stud and weled. time I was done I had used 30 nuts, and 6 arc welding rods.
 
gotcha . ill give that a try luckly i only got one to take out and counting that one 3 to helicoil
 
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