Thread: TD5 exhaust stud.

I haven't actually tackled the job myself but have 'been there'
Had it happen twice on the previous D2, second time the studs were all replaced (after the manifold was machined) with Stainless Studs. My new(er)D2a had already been done by the same mechanic with the SS units. He swears that since he started doing this, he's never had to do a repeat performance. My current vehicle was done 60k ago and so far so good.
Onlt reason I posted this was to tell you about the SS studs.

There are a stack of threads on this, including a couple of "how to's"

Just search for warped manifold, and you will find what you are after.

Its not a hard job, but you will have to move ac compressor which means loosening the serpentine belt.

The other tip is to drill out the outer holes (4 from memory) to the next size up. Leave the ones in the middle as locating holes. This give the manifold room to move without warping.

Oh, and dont forget to remove the webbing.

When I did mine, I stayed with the same size studs as original, so that IF I do have to do it again, I have the option of going bigger. But, 6 months on, so far, so good.

I done the same stud on my 99 defa and was able to do it by unbolting the A/C and swinging it back on the pipes without removing it altogether. Wish I had known about the stainles studs though.

Originally Posted by Basil135

There are a stack of threads on this, including a couple of "how to's"

Just search for warped manifold, and you will find what you are after.

Its not a hard job, but you will have to move ac compressor which means loosening the serpentine belt.

The other tip is to drill out the outer holes (4 from memory) to the next size up. Leave the ones in the middle as locating holes. This give the manifold room to move without warping.

Oh, and dont forget to remove the webbing.

When I did mine, I stayed with the same size studs as original, so that IF I do have to do it again, I have the option of going bigger. But, 6 months on, so far, so good.

I drilled mine out also but still found that,in two cases, the studs were still hard up against the manifold holes. So I filed those two out to give a little clearance and allow movement. Stuck with original size studs and no problem since.

bear with me here,,,
just asking OK?

but IF you do that,, (allow movement) doesnt that mean that "its" loose?

seems to me (uneducated but interested in this type of stuff V8 owner) that it would blow gaskets?

This seems to be a common problem, but can anyone tell me : Is this more likely to happen with a chipped and upgraded TD5, or will a stock standard engine suffer as well ? Also, is it more common when towing? Reason I ask, haven't had it happen yet, but would do the mod. if it was necessary. I take it high EGT's are the cause? Bob

It is expansion due to heat that causes it so yes chipped Td5 are more likely if you drive them with high egt. Td5s that tow are also likely due to the high throttle input resulting in high egt. But it has happened to both chipped and unchipped.

Thanks for the advice fellas. will tackle it in a week or 2.

Cheers