[DML] Broken Exhaust Manifold Stud

["dadoc2791" <gekko@xxxxxxxx>]

I have recently developed an exhaust leak and after investigation, I 
have found that I have a broken exhaust manifold stud.  It is broken 
off almost even with the surface of the head, so nothing to grab 
hold of with the vice grips, etc.  Since I haven't been under there 
tweaking on the nuts, I have to assume it's been that way for some 
time but the exhaust manifold gasket finally gave up the ghost and 
is allowing exhaust gasses to leak by.

Fortunately for me, it is the rear-most stud on the left side which 
is (the only one which is) accessible without removing anything, 
even the catalytic converter.

The way I see it, I have 3 options for repair.
 
1.  Drill out and replace with an oversized helicoil. (could be a 
problem with space in the aluminum head - water jackets, etc.)

2.  Drill out the entire stud and re-tap the hole (probably a bit 
larger than stock)to replace the stud or bolt.

3.  Drill the stud with a small bit (3/16" or so), drive an "E-Z 
out" into it and unscrew the stud, replace with new one.

My question is, which of these is the preferred method?  I'm sure 
this is not an unusual problem.  How have 'we' found is the best way 
to address it?

Thanks in advance for your help.

Craig Werner
 0781



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