Broken Stud
Thread Starter
Drifting
Joined: Mar 2001
Posts: 1,411
Likes: 2
From: St. Louis, Missouri
Broken Stud
I’m in the process of removing the OEM exhaust from my ’79. In doing so, I broke one of the studs that mount the Y-pipe to the exhaust manifolds. I tried threading two nuts and using one against the other as a jam nut to remove the stud but it looks like the break wasn’t clean enough and the threads are too distorted to thread a nut or two.
Before starting, I soaked the studs down with PB Blaster. The stud that broke is the inboard driver side stud. I can’t drill it out from above because the manifold and block are in the way. I’m afraid to grab the stud with vise grips because I don’t think it will grip tightly enough to remove the stud.
The next option I could think of would be to remove the manifold but I am reluctant to do this in fear of breaking a manifold bolt off in the head.
Any suggestions?
Before starting, I soaked the studs down with PB Blaster. The stud that broke is the inboard driver side stud. I can’t drill it out from above because the manifold and block are in the way. I’m afraid to grab the stud with vise grips because I don’t think it will grip tightly enough to remove the stud.
The next option I could think of would be to remove the manifold but I am reluctant to do this in fear of breaking a manifold bolt off in the head.
Any suggestions?
Heel & Toe
Joined: Feb 2006
Posts: 22
Likes: 0
Hi, I found a stud remover at Sears that works realy great.I had a broken body mount stud when doing my off the frame resto and couldn,t budge it w/ heat or vise grips pb blaster cussing at it pouring beeer on it ect. weel this 25.00 set of stud removers took it right out.
Race Director
Joined: Jul 2004
Posts: 12,672
Likes: 329
From: Scottsdale Arizona
I think that you've already figured out the problem and the solution.
Soaking the stud in PB blaster or Kroil will give you the best chance of removing the stud in place. I'd suggest a couple of days of treatments. You could try heat as well, but I'm not sure how much that'll help an exhaust manifold stud.
Vise grips are probably as good a tool as any to try to remove the stud. Tom's idea of the stud remover may work as well. I've had luck sometimes with an impact wrench on "gentle" against the jam nut to loosen it. Thoug, some of the stud removers are advertised as impact grade as well.h I've never tried it
Bottom line is that the stud is likely badly rusted and fused to the manifold. I've almost always found that the stud likes to shear off almost flush with the manifold. At that point, pretty much your only option is to remove the manifold, take it to a mahine shop and have it drilled out. Probably need a helicoil as well.
Soaking the stud in PB blaster or Kroil will give you the best chance of removing the stud in place. I'd suggest a couple of days of treatments. You could try heat as well, but I'm not sure how much that'll help an exhaust manifold stud.
Vise grips are probably as good a tool as any to try to remove the stud. Tom's idea of the stud remover may work as well. I've had luck sometimes with an impact wrench on "gentle" against the jam nut to loosen it. Thoug, some of the stud removers are advertised as impact grade as well.h I've never tried it
Bottom line is that the stud is likely badly rusted and fused to the manifold. I've almost always found that the stud likes to shear off almost flush with the manifold. At that point, pretty much your only option is to remove the manifold, take it to a mahine shop and have it drilled out. Probably need a helicoil as well.
Last edited by CA-Legal-Vette; May 26, 2006 at 10:25 AM.
Thread Starter
Drifting
Joined: Mar 2001
Posts: 1,411
Likes: 2
From: St. Louis, Missouri
I just Googled it. May be worth a try. Thanks.
Originally Posted by tomcatt
Hi, I found a stud remover at Sears that works realy great.I had a broken body mount stud when doing my off the frame resto and couldn,t budge it w/ heat or vise grips pb blaster cussing at it pouring beeer on it ect. weel this 25.00 set of stud removers took it right out.
Thread Starter
Drifting
Joined: Mar 2001
Posts: 1,411
Likes: 2
From: St. Louis, Missouri
Of the six studs, I'm a little surprised that “only” one broke. Of course it had to be the least accessible one. The other five came off easily. My typical luck when working on cars. Nothing ever goes start to finish cleanly.
Originally Posted by CA-Legal-Vette
I think that you've already figured out the problem and the solution.
Soaking the stud in PB blaster or Kroil will give you the best chance of removing the stud in place. I'd suggest a couple of days of treatments. You could try heat as well, but I'm not sure how much that'll help an exhaust manifold stud.
Vise grips are probably as good a tool as any to try to remove the stud. Tom's idea of the stud remover may work as well. I've had luck sometimes with an impact wrench on "gentle" against the jam nut to loosen it. Thoug, some of the stud removers are advertised as impact grade as well.h I've never tried it
Bottom line is that the stud is likely badly rusted and fused to the manifold. I've almost always found that the stud likes to shear off almost flush with the manifold. At that point, pretty much your only option is to remove the manifold, take it to a mahine shop and have it drilled out. Probably need a helicoil as well.
Soaking the stud in PB blaster or Kroil will give you the best chance of removing the stud in place. I'd suggest a couple of days of treatments. You could try heat as well, but I'm not sure how much that'll help an exhaust manifold stud.
Vise grips are probably as good a tool as any to try to remove the stud. Tom's idea of the stud remover may work as well. I've had luck sometimes with an impact wrench on "gentle" against the jam nut to loosen it. Thoug, some of the stud removers are advertised as impact grade as well.h I've never tried it
Bottom line is that the stud is likely badly rusted and fused to the manifold. I've almost always found that the stud likes to shear off almost flush with the manifold. At that point, pretty much your only option is to remove the manifold, take it to a mahine shop and have it drilled out. Probably need a helicoil as well.
Race Director
Joined: Jul 2004
Posts: 12,672
Likes: 329
From: Scottsdale Arizona
Originally Posted by Neo Fender
Of the six studs, I'm a little surprised that “only” one broke. Of course it had to be the least accessible one. The other five came off easily. My typical luck when working on cars. Nothing ever goes start to finish cleanly.
Melting Slicks
Joined: Aug 2003
Posts: 2,135
Likes: 2
From: Dayton Oh
Heat, lot's of heat. At worst it will take some temper out of the stud and then you can drill and tap it. If it were me then I'll attempt to remove the manifold so that I could put it on the work bench and get down to serious 
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