[DML] Re: Broken Exhaust Manifold Stud

["Dave Swingle" <swingle_dmc@xxxxxxxxxxx>]

#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.
>



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