Re: [DML] Broken Exhaust Manifold Stud

[DMCVIN6683 <dmcvin6683@xxxxxxxxx>]

Spray it with plenty of Gibbs or PB Blaster penetrating oil and let  
it soak overnight. whack it with a hammer the next day and repeat the  
penetrating oil. Do this for a few days.

Get a 5/32 Left hand drill bit. A left hand drill bit uses the  
reverse speed of the drill so hopefully as you drill into it the  
drill may loosen it up and back it out the same time. I bought my bit  
on EBay. Local stores dont seem to carry them for some reason. You  
can also find them online if you dont like EBay.

Make sure you mark off the depth with a piece of electrical tape on  
the drill bit so yo dont accidentally drill deeper than the broken stud.

If the stud doesn't back out when drilling you will have to use some  
type of stud extractor to remove the stud.

I did this on my broken off flush stud and it worked flawlessly.

Mark V




On May 25, 2007, at 2:05 PM, dadoc2791 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.
>
> 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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