Resolved Stock head exhaust studs break with 230 hp!!??

[SRiz]

ok well i took my heatshield off for the first time since i had my car and i find a stud wittout a nut... ok w/e ill get a factory nut ..WRONG.. i try to put one of the other ones on there and pop comes the head stud so i got the new stud washer and nut from the factory but now i have that damn stud still in the head ive tried EZout maybe my drill isnt stong enough but it didnt even penetrate!!! should i just get a machine shop to fix this i dont want to spend too much!! HELP please

 

[temfate]

That is not a head stud, it's a exhaust manifold stud, and yes, they are known to break very easily on the outside ones. The best advice I've seen on it is to use a die grinder with a carbide drill bit to get into it, then use a extractor... And make sure you don't go all the way threw, you don't want to go into the head!

 

[Lunch_Box]

It is very common for exhaust manifold studs to break as the rust on and are snapped easily.

 

[SRiz]

ive tried drilling it starting from a very small drill and working my way up but the smallest one wont even drill in it.... my freind said get a high voltage drill with steel bits im going to home depo tmr can u tell me exactly what to get..
thanx.
Sam

 

[Mike1992]

That is not a head stud, it's a exhaust manifold stud, and yes, they are known to break very easily on the outside ones. The best advice I've seen on it is to use a die grinder with a carbide drill bit to get into it, then use a extractor... And make sure you don't go all the way threw, you don't want to go into the head!

I had the same problem about 3 weeks ago except it was 3 broken studs in the head The absolute best thing is a carbide bit and a die grinder (air style) I musta drilled with a drill for 2 days and didnt get near as far as I did in 10 minutes with a die grinder and a carbide bit.

 

[TimG]

I've broken one and realized why. If you take one out at a time, they will all break. If you back one out 1/4 turn, then another a 1/4 turn, then another 1/4 turn, then the last a 1/4 turn and keep doing this, they shouldn't break.

Either way they are SHIT. I use main stud bolts to hold my turbo. They are amazing bolts. Right out of the bottom of the 4G63.

 

[SRiz]

ok... i finally got a starter hole... now what size ez out should i use... theres like 3 that will fit it do i want to get like milimeters away from the tread or have a good distance an have less leverage... i cant seem to get the ez out in and turn the thing out...... can someone explain exactly so to use an ezout drill bits

 

[Mike1992]

Drill it a good 1/8" to 1/4" If you dont drill it deep enough (to deep is bad also, don't drill into the head) your liable to break the eazy out in it and then your ####ed. Im telling you man, your gonna be there forever with drill bits. Get a CARBIDE bit. The more eazy out in the stud the better you are. If you can only get a little bite the eazy out will break.

 

[SRiz]

ok thank god!!! its out... i dunno if i went to far i dont see any coolant thats good ... ok well my threads are fudged up now with all the messing around in there and i got the bits to fix it and ones too small and the others are to big heres a pic of em which one should i use should i just go ahead and put my new stud in with it like it is below or put the bigger size thead fixer bit in first?

 

[Xero_Tolerance]

When the same thing happened to me I just used a 10mm tap instead, although I guess a 9 would be fine but I couldn't find any good 9mm studs... So you can tap up to 10mm or helicoil back to 8mm. If you can helicoil I would do that becaue the 10mm ones are going to be just as likely to strip but a helicoil is steel so supposedly it is less likely to strip out. I haven't been able to get my manifold sealed for months now since all but one of my studs came out when I took my manifold off so I'm just going to take mine to a machine shop and get them to put new ones in, but since you're only missing one I bet it's not affecting performance much at all anyway so a bigger tap should be good.

Note: If you do go 10mm you'll have to widen up the manifold holes a bit.

 

[mavisky]

I heli-coiled every exhaust stud I have as well as some of the valve cover bolt holes and those suck to heli-coil if you've never done it yet.

 

[Xero_Tolerance]

Does anyone know an estimate of how much a machine shop would most likely charge to get all of your exhaust manifold studs helicoiled?

 

[jonk00000]

I'm going through the same problem rite now. Maybe someone can help. one of my manifold bolts broke off in the head. I drilled a hole in it then snugged an extractor into the bolt.I slowly loosen the bolt out and about a half a turn later, the extractor breaks in the bolt. I cant drill it again b/c a drill bit wont penetrate the piece of extractor. some one please help thanks jon

 

[marcmsj]

is there an alternative to OEM exhaust manifold studs?

 

[igopoopy]

http://www.ssstuds.com/

 

[Mike1992]

I'm going through the same problem rite now. Maybe someone can help. one of my manifold bolts broke off in the head. I drilled a hole in it then snugged an extractor into the bolt.I slowly loosen the bolt out and about a half a turn later, the extractor breaks in the bolt. I cant drill it again b/c a drill bit wont penetrate the piece of extractor. some one please help thanks jon

Same happened to me, DIE GRINDER AND A CARBIDE BIT DID THE JOB IN ABOUT 10 MINUTES.