broken manifold stud

M

MikeSyclone

New member
hey guys i snapped off one of the manifold studs that the turbo sits on......the turbo is out but now i have to deal with this broken stud. its flush with the manifold so theres no welding something to it. i was thinking about drilling it out with an angle drill but i would destroy the threads. i planned on swapping out all the studs and use bolts instead so it will be easier to remove in the future so i guess its not tooo bad if i ruin the threads.

anyway, so anyone have a good method to remove this thing with out removing the exhaust manifold from the truck
 
James Thomas

James Thomas

"NO CLASS"
Re: broken manifold stud

If you don't have good experience in removing broken bolt / studs etc. and don't have a cutting torch and drill press. I recommend that you take it to a machine shop and just let them do it. If you break an "easy out" off in there you will not be happy. At least a machine shop can chuck it up straight, drill it through and heat it to remove it and likely with out damage, or at least Heli-Coil it.

___________
James
 
TYTILIDIE

TYTILIDIE

METH HEAD
Re: broken manifold stud

X2, dont even mess around with it. I did this to a cylinder head a few years back and like a dolt, I totally screwed up the hole. A machine shop hee had to use a carbide bit to get it out and then had to helicoil the hole. Luckily, the guy was right on target and fixed it perfectly. He even did it on a saturday @ 11:30am just before the 12 noon closing time. Toook him about an hour or two. Cost me $150. $75, Saturday closing time labor.
 
C

CKEITH

Doghouse Member
Re: broken manifold stud

MikeSyclone said:
i was hoping to not have to remove the header...ugh
Click to expand...


mike get you a small drill bit and matching easy out......taking your time and patience..slowly drill the center of the broken stud....you will find that the surface of the broken stud seems rather hard to drill...almost as if the bit just spins without biting in....still being patient...keep drilling....once it hits some meat it will actually dig thru pretty fast.

soak the stud w/ pb blaster real good and let it sit for a while...then take the easy out and lightly tap it into the hole you drilled.....apply a bunch of heat from the propane cylinder....real freaking hot. and still patiently slowly back the stud out....if it hangs up or seems to go nowhere you can release the easy out be turning it the other way....tap it back into the hole and continue....

the tapping with the hammer and extense heat will remove the stud...you just have to be patient and don't over work the easy out.

has worked many times for me in the past on many many rusted/frozen studs. :2cents:
 
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