Broken exhaust manifold stud!
Thread Starter
Instructor
Joined: Jul 2001
Posts: 189
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From: Berkeley Heights New Jersey
Broken exhaust manifold stud!
My connections between the exhaust pipe and manifolds are leaking. I sprayed WD40 on them for the last week. Today I tried to tighten on of them and snapped off part of the stud. Does anyone know how to remove the rest of the stud and free up the other one before they break too?
Le Mans Master
Joined: Aug 2001
Posts: 7,804
Likes: 4
From: Standing still with all my might Texas
Cruise-In X Veteran
St. Jude Donor '09-'11
Re: Broken exhaust manifold stud! (bl75vette)
I had to replace all 6 of mine right after I bought my 73. You will need to remove the manifold and use lots of heat (I used a propane torch) and lots of penetrating oil. Just soaking overnight worked on some of them, altenating heat and oil (watch out though, WD40 is flamable) worked on others, but two of them broke off and I had to use an easy out on them.
It helps to have a big vise to hold the manifold while you are working on it, and I used a Vise Grip to grab the old stud. If you have to resort to the easy out I found that it helps to grind the end of the bolt flat with a cutoff wheel before drilling, that way the bit doesn't wander as much and you have a better shot at getting the hole centered in the stud.
I installed the stainless steel stud kit from Volunteer Vette in mine and I haven't had any trouble since, there are also some available with brass nuts that work good too. I would also suggest getting the metal doughnut instead of fiber. I had 3 of the fiber ones fail on the passenger side before I found out about the metal ones.
Another suggestion would be to get new manifold to head bolts, those tend to corrode and rust as well and as long as you have the manifolds out it is worth it to replace them.
It helps to have a big vise to hold the manifold while you are working on it, and I used a Vise Grip to grab the old stud. If you have to resort to the easy out I found that it helps to grind the end of the bolt flat with a cutoff wheel before drilling, that way the bit doesn't wander as much and you have a better shot at getting the hole centered in the stud.
I installed the stainless steel stud kit from Volunteer Vette in mine and I haven't had any trouble since, there are also some available with brass nuts that work good too. I would also suggest getting the metal doughnut instead of fiber. I had 3 of the fiber ones fail on the passenger side before I found out about the metal ones.
Another suggestion would be to get new manifold to head bolts, those tend to corrode and rust as well and as long as you have the manifolds out it is worth it to replace them.
Burning Brakes
Joined: Jan 2001
Posts: 1,218
Likes: 2
From: Plainfield IL
Re: Broken exhaust manifold stud! (bl75vette)
Bl75Vette--I once had the same problem. I went to a muffler shop and the mechanic welded a bolt to the broken stud. Next, he heated the area around the stud with a torch; then he unscrewed the stud using socket wrench.
I prefer using Liquid Wrench over WD40 for loosening old fasteners. It seems to penetrate better.
I prefer using Liquid Wrench over WD40 for loosening old fasteners. It seems to penetrate better.
Race Director
Joined: Nov 2000
Posts: 16,416
Likes: 1
From: NC,USA
Re: Broken exhaust manifold stud! (Biker)
I am in the process of pulling the manifolds to replace the studs :cry
The the plate that was on the old exhaust system had been filed down to fit on :eek:
hope you get it out
ZD
The the plate that was on the old exhaust system had been filed down to fit on :eek:
hope you get it out
ZD
Thread Starter
Instructor
Joined: Jul 2001
Posts: 189
Likes: 0
From: Berkeley Heights New Jersey
Re: Broken exhaust manifold stud! (ZD75blue)
Thanks guys for all your input. I guess I'll pull the manifolds during the winter months and play with the studs. If not successful, I guess I will confide in Midas or Meinike.
