#1. You don't really want to go to a bigger stud - that means centering and drilling the manifold too. I've yet-to-ever see an EZ-out actually work, and once it breaks off, you are really in a world of hurt since it is now harder than the drill bit. A good thing to try is to chase down your local Snap-On or other tool guy truck and get a set of left-handed drill bits. First - since they are new they are sharp. Second, sometimes you get lucky and the combination of heat and left-handedness backs the stud out. The hardest part about #3 is actually finding someone to sell you a 7 mm heli-coil. They are out there, but you won't find it at Sears or Ace. Dave S --- In dmcnews@xxxxxxxxxxxxxxx, "dadoc2791" <gekko@...> wrote: > > 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. > To address comments privately to the moderating team, please address: moderators@xxxxxxxxxxx For more info on the list, tech articles, cars for sale see www.dmcnews.com To search the archives or view files, log in at http://groups.yahoo.com/group/dmcnews Yahoo! Groups Links <*> To visit your group on the web, go to: http://groups.yahoo.com/group/dmcnews/ <*> Your email settings: Individual Email | Traditional <*> To change settings online go to: http://groups.yahoo.com/group/dmcnews/join (Yahoo! ID required) <*> To change settings via email: mailto:dmcnews-digest@xxxxxxxxxxxxxxx mailto:dmcnews-fullfeatured@xxxxxxxxxxxxxxx <*> To unsubscribe from this group, send an email to: dmcnews-unsubscribe@xxxxxxxxxxxxxxx <*> Your use of Yahoo! Groups is subject to: http://docs.yahoo.com/info/terms/