Snapped exhaust manifold studs

[Rich Hanlon]

Right, here's hoping.

Say, for example, I'd managed to snap off the exhaust manifold studs which are directly over the starter motor and inaccessible behind the engine cradle. I'm guessing the only way to get at them to drill out and re-tap is to pull the engine out - am I right?

Any secret techniques out there, or am I looking at No More Delorean for the next few months?

Rich

PS - Why does a straightforward job always become a massive job that writes off the most enjoyable months of the whole year? I really am getting fed up with this...

[stunned_monkey]

While I've heard from people who've successfully drilled studs out in situe, I always pull the head if I get a snapped stud flush with the head. If you've got something to get hold of, get a propane torch on it and use a decent stud extractor (I use a Teng 6mm), then helicoil the hole after it comes out. The studs are a lot easier to drill out on a pillar drill with the head sitting perfectly square, and you can guarantee a good thread when you're done helicoiling.

OR, buy the stainless system and use the opposite holes.

[Rich Hanlon]

It all sounds like fun eh? (Grits teeth!!!)

Thanks Martin, I'll keep you all posted!

[stunned_monkey]

If it makes you feel any better, what started out on 4772 as a simple engine tidy up ended in a complete strip down to repair a stuck valve, pitted liner and finally to weld up one of the liner seats which had corroded though. Had it not been for the stuck valve, I'd never have found the other two till the car was nearly ready... Spent 2 hours today grinding in the liner seats. I always get a blister on the same knuckle doing that job....

It's funny: when you know just how bad any job can possibly get, anything less is "easy"

[Rich Hanlon]

Thanks for that! True, it could be worse, but feeling pretty deflated right now!!

By extractors, you mean like these?

http://cgi.ebay.co.uk/1-2-SQUARE-DRIVE- ... 19b8dce8da

or like these

http://cgi.ebay.co.uk/S46925-Stud-Extra ... 3a5d305689

I have one stud snapped flush, but can just get the drill to it with the alternator off. I have easy-outs at the ready purchased for this as this is the one I knew about - and the reason the manifold had to come off in the first place. The other has left a stub about 8mm long once the manifold comes off, but is much less accessible behind the 'cradle'.

Plus, two studs still to go, haven't got them yet as I can't get the sodding starter-motor heatshield off. Deep-drive 11mm 3/8" drive socket needed - has to be a six sided one. Have tried a 12-sided and it's all gone nice and round. Joy...

R

[stunned_monkey]

manifold studs often snap off at the nut so you can grab onto what's left - I wouldn't worry about it, they almost always come right out.

I mean the second type of extractor, but don't buy a cheap one - I destroyed a halfords 6mm one after 2 studs. My £10 Teng one is still working several years and a helluva lot of studs later. You have to hit it on with a hammer. Also bang it totally flush with the head because you're then only applying torque and tension at the moment of release, no bending

http://toolstoday.co.uk/shop.php?sec=prod&prod=51801

[Guinney1971]

thats true Martin, I remember how cack those stud extractors were that
Verity and I spent an afternoon trying to locate and buy when Flopsy's
engine first came apart.

[Rich Hanlon]

Thanks all!

Hope it'll get through the MOT with a blowing one, then I can start properly once that's out of the way...

[dmc4087]

I had 2 broken studs to remove. We drilled a small hole into the stud, then hammered a torx bit into that hole. It had enough grip to turn the stud out.

My engine was out of the car but could you get a 90 degree extension in there, or even a dremel?

[Rich Hanlon]

I may be able to - the one that has snapped off flush with the cylinder head is accessible with the alternator off - so can get a drill to that from underneath and do as you say. The one above the starter motor has left a small stub I might be able to work with. If that snaps off though, it might be worth looking at getting a 90degree drill head in there or something....

Fun fun. MOT tomorrow. Will slap it all back together (very) temporarily using what studs are left and hope he's in a good mood...

[dmc4087]

One of mine left a bit out, I tried knocking it round with a drift but the stud was too soft.

I tried mine with a stud missing (temporarily), it didnt seal but good luck!

[Rich Hanlon]

Put it all back together, and it sounds terrible. Not a hope of an MOT!!

Cancelled appointment!

[Guinney1971]

bit like Flopsy was when I first fired her up back in 2002 - she sounded
like a Massey Ferguson with a hint of 80 grit badgers bottom for good
measure :lol:

[Rich Hanlon]

Sounds familiar! Engine out job I'm afraid. Rear fascia, fibreglass panel etc off already, ditto back box and alternator and assorted bracketry. What fun!

[dmc4087]

Not tempted to do a frame off 'while you're in there'?