Head to Manny Studs are a PITA!!!!

[Mike1992]

So I get the new tsi home last weekend, and start pulling her apart to replace the locked up turbo. After everythings off Im stuck with 3 busted studs in the head. Sheesh after some thinking and searching on how to get these lil fookers out i decide to drillem out and use an easy out. Best I could buy?, hmm SEARS. So I get on the first stud, takes about 45 mins to get it drilled enough to get the easy out in and comes out easily. Sweet onto #2 Drill for a good 45mins insert the easy out and SNAPPPPPPP!!! OHHHH MOTHER F*&^%*^% So here I am a day wasted, trying to drill this POS out and it seems like Im getting nowhere fast I do not wanna pull this head, but I do want this fricking stud out. My next option is to get ahold of an air compressor and use my die grinder with a carbide bit and go at it some more.

I know a few of you know what im talking about, HELP ME PLZ GOD!
Where is that magical tool that does all the work for you?

 

[loweperf]

Welcome to my world! I own an auto repair/speed shop and this is the kind of stuff we do everyday. There is no magic tool, You are doing it the right way it just takes time and patience(although years of experience helps)sometimes they come out sometimes not. I have a range full of chisels,punches,drills,wd40,wax,torches,easyouts,and inserts for when they don't come out. This is what I often think of when a customer complains of a quote for 3 hours and they think it should only take 2.

 

[blcknspo0ln]

so this is why PB BLASTER, a torch, and a big f-ing breaker come into play.

goodluck because i still have one bolt stuck in the head

 

[Mike1992]

Well, the one on the bottom next to the very left one is now a lost cause. That one wins the battle. Tomorrow I'll attempt the last one on the far bottom right behind the power steering pump

 

[onegee]

After you get out the stud behind the P/S pump, replace it with a bolt instead. Its alot easier to get to and makes it easier to pull the head straight up with ARP headbolts.

Just a tip that was passed on to me.

Good luck and TAKE YOUR TIME. Its a painstakingly annoying and long procedure so if you rush it, more things go wrong. Dont ask me how I know.

Seriously though, hope you get it out.

-R

 

[Mike1992]

I already ordered new SS Studs, so that what I'll end up using. My dad says the gaskets gonna blow I fi dont get the stud out what does everybody think on that? Will it leak without a stud in the center? I will be using a metal gasket...

 

[Tallen]

I've always used reverse cutting drillbits with much success, the heat and drillbit grabbing the metal usually loosed them, if they don't come out 100%, I pound a Torx bit into the hole andcrank it out.
Easy outs breaking require the use of a nice expensive carbide drill bit...eek.

 

[Tallen]

I've always used reverse cutting drillbits with much success, the heat and drillbit grabbing the metal usually loosed them, if they don't come out 100%, I pound a Torx bit into the hole and crank it out.
Easy outs breaking require the use of a nice expensive carbide drill bit...eek. It will leak w/o any stud.

 

[Mike1992]

I brought one of the snapped off bolts to my shop and tried out my die grinder and a carbide bit on it. Wow, I should started with this in the first place. Now to go off and buy a portable air compressor and get on this for real.

 

[Mike1992]

Well the carbide bits matched with my die grinder made easy work of the broken off studs. I musta only spent 10 minutes and they were out. Thank GOD!!! The online vendor I ordered new SS studs from didnt think to call me and tell me they were on back order for another 2 weeks, so I dealt with that problem and went and bought some bolts from the hardware store and got the turbo assembly installed. All is well in the land of DSM.

 

[temfate]

Thanks for your story here, I have 2 or 3 broken studs in mine from the owner before me putting on a 2nd gen manifold. I have done my best to ignore them hoping they'd go away, but alas I'm getting tired of that exhaust leak... I have a die grinder, what drill bit did you use? And what extractor? Is a easy out a extractor or something else??

 

[Mike1992]

I used CARBIDE bits usually used for porting, I got mine off ebay long ago and they havent dulled at all on anything Ive tried them on. The extractor I used was an easy out set that I got from sears, works dandy. Good luck with your project, this is definetly the way to go, drill bits did didly for nearly 6-10 hours of off an on drilling, when the carbide bit and a die grinder took 10 minutes.

 

[slvrstingray]

Mike--

you should consider drilling out and tapping the outer 2 studs and converting them to from the 6mm stud to the 8mm, or is it (8mm to 10mm??) stud like the 2g's.... anyway, they are stronger and less prone to snapping.

 

[steve]

You should consider drilling out and tapping the outer 2 studs and converting them to from the 6mm stud to the 8mm, or is it (8mm to 10mm??)

It's 8mm to 10mm.

Steve

 

[DSM_Roller]

Is anyone using ARP studs?

 

[Mike1992]

Its already bolted up and I retapped them all to 8mm, I feel as though the new stainless bolts will hold up great though. I appreciate the input.