Dropped exhaust, sheared stud in process. What now?!?!
Thread Starter
Melting Slicks
Joined: Oct 2005
Posts: 2,159
Likes: 2
From: Stillwater, OK
Dropped exhaust, sheared stud in process. What now?!?!
I had to drop my exhaust to install a starter. I sheared one of the studs on the header manifold that connects to the exhaust pipe on one side, I got the other two snug but I still have an exhaust leak. This is the stock exhaust and header. How do I remove the busted stud and replace it? I can't see how to under the car. Can I drill it out and drop a bolt through it? I'm lost. The leak isn't bad, but it's noticeable. It idles more roughly but it's not major.
Thanks
Thanks
Race Director
Joined: May 2005
Posts: 15,960
Likes: 21
From: West Norriton PA
St. Jude Donor '08
I had to drop my exhaust to install a starter. I sheared one of the studs on the header manifold that connects to the exhaust pipe on one side, I got the other two snug but I still have an exhaust leak. This is the stock exhaust and header. How do I remove the busted stud and replace it? I can't see how to under the car. Can I drill it out and drop a bolt through it? I'm lost. The leak isn't bad, but it's noticeable. It idles more roughly but it's not major.
Thanks
Thanks
You can buy them for a few bucks at the dealer. They just screw out.
Spray some rust penetrating oil on the stud and grab it with some vice grips.
Some heat from a torch might help break it loose.
Thread Starter
Melting Slicks
Joined: Oct 2005
Posts: 2,159
Likes: 2
From: Stillwater, OK
Race Director
Joined: May 2005
Posts: 15,960
Likes: 21
From: West Norriton PA
St. Jude Donor '08
Melting Slicks
Joined: Oct 2007
Posts: 2,798
Likes: 8
From: It's true money can't buy happiness, but it is more comfortable crying in a Corvette than on a bicyc
St. Jude Donor '13
It won't just screw out. Even with two days of penetrating spray. When mine broke I knew the headers were coming soon so I drilled through the bolt and used a stainless nut and bolt. A few months later it came free easy, what didn't was another bolt on the drivers side. It had been removed when I broke the first one during the clutch install.
For what it's worth the bolt is so soft I drilled through it with just a cheap 18 volt cordless drill in a couple minutes.
For what it's worth the bolt is so soft I drilled through it with just a cheap 18 volt cordless drill in a couple minutes.
Thread Starter
Melting Slicks
Joined: Oct 2005
Posts: 2,159
Likes: 2
From: Stillwater, OK
It won't just screw out. Even with two days of penetrating spray. When mine broke I knew the headers were coming soon so I drilled through the bolt and used a stainless nut and bolt. A few months later it came free easy, what didn't was another bolt on the drivers side. It had been removed when I broke the first one during the clutch install.
For what it's worth the bolt is so soft I drilled through it with just a cheap 18 volt cordless drill in a couple minutes.
For what it's worth the bolt is so soft I drilled through it with just a cheap 18 volt cordless drill in a couple minutes.
Race Director
Joined: May 2005
Posts: 15,960
Likes: 21
From: West Norriton PA
St. Jude Donor '08
Just remove the exhaust manifold from the car to make it easier.
Melting Slicks
Joined: Apr 2003
Posts: 2,150
Likes: 6
From: NS
I think these are 10x1.5 metric studs (not sure). So first drill it out first with a small pilot hole exactly in the center of the stud and straight. Then drill using a 5mm drill. Finally, drill with an 8.5mm drill and if you're lucky and have drilled a nicely centered pilot hole, you will be able to easily pick some of the old threads out of the hole. The last step is to run a 10x1.5mm tap through the hole and then it's as good as new.
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
Top 10 Most Expensive Corvettes Ever Sold on Bring A Trailer
Brett Foote
10 Things Every Corvette Owner Needs (2026 Edition)
Michael S. Palmer
8 Most "Only Corvette Owners Understand" Quirks and Problems
Pouria Savadkouei
10 Reasons the C6 Z06 is Still A Performance Benchmark After 20 Years
Joe Kucinski
How Much Horsepower Every Corvette Engine "LOST" in 1972
Joe Kucinski
Top 10 DOs and DON'Ts for Protecting Your Convertible Top!
Michael S. Palmer
Top 10 Most Explosive Corvettes Ever Made: Power-to-Weight Ratio Ranked!
Joe Kucinski
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Team Owner
Joined: Mar 1999
Posts: 22,025
Likes: 192
From: At the beach in little Rhody
The studs are very soft weak metal. I removed mine within months of the car being built and they started to twist on me, so much longer they will break. If you can center punch it then drilling will work. Otherwise soak in PB and hope for the best. An exhaust shop will heat it cherry red and get it out but you will have to pay for that service.