Thread: Broken Exhaust Manifold Stud

if you have the manifold off mostly the leftover stud will come out with the edge of a chisel driving it in the direction of undo. If you are DIYing start by giving it plenty of freeze'n'release while its hot and following that up with lots of penetrating spray lube while you take your time pulling the manifold

IF i think I need to help one along, (time not being an issue and there's no need to run the extra risk of more invasive methods) I recover the coolant from the engine, heat the area with a hot air gun to about 200 degrees then drive it with the chisel,

next step is left hand drills

then rigid stud extractors

Then drill outs

then ezy outs

then a bit of a sit and a think.

Thanks Dave, as it is cylinder 5 (on a TD5), can it normally be done without removing the head?

Ian

Im 6/6 so far and one of them didnt even require removing the manifold (owner wanted it done in under an hour, it came out on the left hand drill)

Thanks Dave, how about moving to Melbourne!!

make sure you shave the manifold before you replace it. This is a common issue with TD5's, especially up the Tourist Rd where they tend to heat up.

Russ,

I do plan to have the manifold skimmed.

BTW, where are you? we are obviously fairly close by.

Ian

Originally Posted by IanP

I have a broken Exhaust Manifold stud (cylinder 5). It appears to be snapped off level with the head surface. There is soot deposit around the area of the missing stud so I am assuming that the manifold is warped as well.

As I am not confident about welding on a nut or trying to drill out the broken stud, I am wanting to get someone else to do the stud removal. Hopefully it will not need the head removed!

I am in the outer Eastern Area of Melbourne (Dandenong Ranges), does anyone know of someone who can do it on site? I know of 'The Thread Doctor' and will be calling him Monday, but does anyone know of anyone else?

It is possible to take it to a workshop but I am happy to do the manifold removal / SS stud replacement etc myself.

Any suggestions welcome!

Thanks
Ian

Ian,

I had a go a two broken studs without success - called the Thread Doctor and he had 'em out in 15 minutes, pulled the ones I couldn't get out and inserted all new studs that I had supplied for $120 (less if you don't need a tax invoice like I did)

Cheers,

Franz

Thanks Franz, did you have the manifold off when he did it?