Need advice on how to remove 2 exhaust manifold studs and one o2 nut

[fourreGsixty3]

OK guys as the title states I need some help. I have searched for some help but I do not come up with the awnser I need, and mostly get threads on how to remove exhaust manifold studs that broke off. I also found this link>>> http://www.vfaq.com/mods/turbo-swap.html, but it also does not help me with exactly what I need. Ok, I have a 92 TSi (stock, but torn apart). I have a garage with all the tools you could need, and it has a large air compressor. I need some ones advice on how they got thrie exhaust mani. studs off. I got all the studs off except 2, the ones that I cant get to are the bottom right side ones, I had to use an impact gun to get these off because not even a regular wrench using the compressor could move these studs, but the impact wrench worked like a dream. The only problem is that I cant get to two of the studs, and they are too tight on there to take off by a wrench. I also used PB Blaster on them twice a day for a whole week before I even attempted to take them off. Also I need advice on how to get the bolt off the o2 housing that goes from the o2 to the turbo, it is the one thats right up front that is easily seen, I PB Blaster it as well for a week, the impact has too big of sockets to fit in there to take it off, and its way to tight to take off by hand. I am truely to the point where Im just going to take an air tool with a cutting wheel to this crappy POS cracked 1G manifold, so I can have a clear path to the studs. Any help would be greatly appreciated,
PS: I will go take pictures today and post them up on here so you guys can see exactly what I am talking about.

Dustin

 

[King Salami]

Dustin -
You may try heating up the area around the seized stud w/ a torch. Between PB Blast & a small propane torch, I've been able to get some pretty nasty bolts out. Be careful with those manifold studs - the head is aluminum & will strip out if you get too medieval on it.

Before reinstalling your new manifold, use a tap/die to clean up the threads on your bolts & mounting holes. And use copper high-temp antiseize on all exhaust hardware.

 

[fourreGsixty3]

Thanks King. I will be taking some pictures soon, and trying your advice on the o2 nut. Also yes, I was planning on cleaning all the threads, and using something to prevent them from seizing next time...along with some nice SS exhaust mani. studs from FFWD. I think Im just going to cut the manifold off (was junking it any ways), so I can just get the impact on the mani. studs.

Dustin

 

[Auto RS T]

Are the studs broken?

http://vfaq.com/mods/wayback/BradBauer/engine/studs.html

If not, have you tried a jam nut? Put a wrench on the jam & use a short pipe for leverage.

For the o2 sensor I would try an o2 sensor socket. With a long extension on it, you should clear obstructions underhood. A little heat would help here also. Otherwise, wait until you remove the manifold and take it off on the bench.

 

[fourreGsixty3]

Thanks Jim, yes there is one stud thats broken, but I know how to remove that (already read that link , I will try the heat thing to get the studs out. Could you elaborate a little more on this jam nut, I will go search now as well on it.

Dustin

 

[Auto RS T]

A jam nut basically gives you a place to put the wrench withouth the nut spinning off the stud. It involves using two nuts, basically putting them into a bind.

First, you run one nut down the stud. Then, you run the second nut against the first & tighten them against eachother. You should be able to put the wrench on the first nut & break the stud free while the second nut holds the first nut in place.

To take the jam apart just loosen the nuts from each other.

 

[fourreGsixty3]

Oh ok, thanks again Jim. I will be going a trying this s right now, and Il be back on here with pics, and the results.

Dustin

 

[fourreGsixty3]

Ok guys I just wanted to bring this thread to an end. I finally go the last two mani suds off, and I got the o2 bolts off as well. I just decided to add up a few swivle heads on with an extension to the impact, and I was able to get a straight connection on the studs. Oh yeah, it turns out that I have 2 studs broken, the last owner snapped one off, bt it was the bottom one right next to the front lift point. Oh and I got some bad news too my turbo hot side is cracked, but it some how works great, but its not too bad since I was already thinking of using it as an awsome paper weight at my apartment. The good news from this is that I will get plenty of porting practice using my exhaust manifold, o2 housing, and 14B as test subjects.

Dustin

 

[Auto RS T]

Glad you were able to get them off without cutting the manifold. Too bad about the 14b, but we knew you weren't going to use that anyway. Let the porting practice commence!

Glad to see you finally got an avatar pic. I always wondered what color your car was...

 

[fourreGsixty3]

Haha, yeah its crappy original paint, I guess it looks OK from a distance...in the shade, squinting but the color grew on me a bit...not enough to keep the colr, but ya know.
Im going to try a few different techniques with porting, I have this air grinder, and it has 36 grit sand paper on it, and its pretty small so I can get good angles with it, and get into lots of places then I will take my dremel to finish everything off, I well try a grinder as well, and try just a dremel. 3 different pieces 3 different techniques On a side note Jim I should have some pics of the front end...soon as a mod OKs them.

Dustin

 

[perley03]

As far as the hot side of the 14b cracking, i think all of them do it. I have 2, one on my car and one i bought at a junkyard for $50, and the are both cracked, in the same place. The one on my car boosted to 13psi by ~3000rpms no prob, and that was before i yanked the engine and fixed all of the exhaust leaks. I have not yet put the motor back in, due to im trying to paint the whole car including the engine bay, and waiting for my tranny and clutch (tranny getting rebuilt synchros, due to 2nd and 3rd grinding.)

 

[fourreGsixty3]

I wasn't putting the 14B back on anyway. GT35R all the way.

Dustin