Thread: TD5 broken manifold stud - is to deferring repair an option?

Naa, it'll just be noisy and the worst that can happen is potential gas cutting of a face, but you'll more than likely have to have the manifold surface ground flat anyway.
The manifold will be warped, that's why the stud is broken

Originally Posted by reefmagnet

I've discovered a broken cylinder 5 lower manifold stud and black soot while doing other work (water pump and oil cooler replacement) on my vehicle. Probably been broken for ages. Normally, I'd fix it while I had access to it, but circumstances at the moment make it preferable to put this off for a bit as I am planning on taking the car on a 2000 km round trip next week (although I could take my Defender ute in a pinch).

Looking for a consensus of opinion. Will I die in a fiery explosion or, even worse, risk costly engine damage if I continue to use the vehicle with the broken stud as is?

You said it. Dunno how long mine was like that. They all do it sooner or later. You can put it off, because i can pretty much guarantee that it won't be as simple a fix as you hope. The manifold is warped ( that's what breaks the stud ), the stud itself can be an absolute **** to get out, and it's worth doing some mods while you are at it to prevent a recurrence. There are some references to it elsewhere here.

Oh, yeah. There are some aftermarket TD5 manifolds available on fleabay. Don't be tempted, they don't fit. Ask me how I know.

Mine has been like that since about the day the bro bought her.
Noticed about 4 years ago now, and approx 60+ K klms ... like Rick said, just noisy(and rough sounding) ...

Have had plans to do it too, but balancing work, finances and doing other work to other vehicles has caused the 4 year delay.
My plan is to get the manifold coated, and I have a place within easy walking distance from home which is a bit of a bonus.
Studs and gaskets were bought a couple of years ago ... still sitting waiting to be used.

Thanks Gents. Yes, I figured it would be a warped exhaust manifold hence why I reckon I wouldn't be able to fix it in time and you guys have emphatically confirmed this! I also suspect I'll break other studs removing the manifold. Had a crack at drilling the broken stud for an easy-out with the manifold in place, but it didn't look promising so aborted that plan!

On the subject, since I will be down Brissie/Gold Coast way next week is there a preferred supplier for grabbing a new manifold gasket and studs that anyone can recommend?

Originally Posted by AK83

My plan is to get the manifold coated, and I have a place within easy walking distance from home which is a bit of a bonus.

Hope he's better than the bloke I used. Stuff just flaked off after maybe a year.

Originally Posted by reefmagnet

I also suspect I'll break other studs removing the manifold.

Possibly not if you give 'em a soak. Mine came off easily.

Originally Posted by reefmagnet

Had a crack at drilling the broken stud for an easy-out with the manifold in place, but it didn't look promising so aborted that plan!

Good luck with that! If you have anything left to grab on to then the advice I had from an indie was to try and tighten it slightly first... didn't work for me. You need to be careful here because you are not that far from the water jacket that you can just drill willy nilly.

Originally Posted by reefmagnet

On the subject, since I will be down Brissie/Gold Coast way next week is there a preferred supplier for grabbing a new manifold gasket and studs that anyone can recommend?

Can't help with a supplier near you. Most folk recommend upgrading the studs to M10, at least on 1 & 5. However, there is no point doing anything unless you get the manifold machined flat. Lots of folk also recommend de-webbing, and enlarging the holes to allow for a little movement. I did that.

Td5 Exhaust Manifold..

td5 exhaust manifold , grinding out the web.

Originally Posted by Tins

Hope he's better than the bloke I used. Stuff just flaked off after maybe a year.

Competition Coatings(Coburg) .. if anyone has heard of or has experience with him.
Chatted to him on phone, then went to see him, he seems like a decent bloke, with zero cow manure type recommendations(eg. taking it to machine shop myself, rather than wasting $s for him to outsource it .. etc).

I'm willing to find out for myself how his quality ends up tho. Manifold has to be done at some point .. just a matter of when.

As well as spray, expect that you may need heat on them too.
I've found one of the best value for money tools I've got was one of those gas bottle top heat guns(ie. butane torch that attaches to disposable gas cans) ... cost about $5 off ebay, and bro used to use the gas cartridges in his (useless) cheapo gas burner.

Gas butane torch head sample on ebay

That kind of thing. Yeah its cheapo, and quality looks like garbage, and the price has tripled in a few years(since I got one) .. but handy little tacker, and if it collapses into a heap of molten plastic, it's still quite cheap to replace.
Never mind that mine has lasted 5 years now.

ps. awesome for starting camp fires!

Originally Posted by AK83

Competition Coatings(Coburg) .. if anyone has heard of or has experience with him.
Chatted to him on phone, then went to see him, he seems like a decent bloke, with zero cow manure type recommendations(eg. taking it to machine shop myself, rather than wasting $s for him to outsource it .. etc).

I'm willing to find out for myself how his quality ends up tho. Manifold has to be done at some point .. just a matter of when.

As well as spray, expect that you may need heat on them too.
I've found one of the best value for money tools I've got was one of those gas bottle top heat guns(ie. butane torch that attaches to disposable gas cans) ... cost about $5 off ebay, and bro used to use the gas cartridges in his (useless) cheapo gas burner.

Gas butane torch head sample on ebay

That kind of thing. Yeah its cheapo, and quality looks like garbage, and the price has tripled in a few years(since I got one) .. but handy little tacker, and if it collapses into a heap of molten plastic, it's still quite cheap to replace.
Never mind that mine has lasted 5 years now.

ps. awesome for starting camp fires!

Def not the bloke I used. I picked him with a pin for expediency. Next time, if there is one, I'd use a shop the hot rod guys go to.