Broken stud connecting exaust system to manifold

[Fran]

The past couple days I've been replacing the clutch in my '05. Pretty much had to take half of he truck to get to it. Getting the exaust off was a huge chore. The last bolt that came off broke. It's in a really tight spot and it's pretty rusted. My tools are limited and I'm thinking of boring through the stud and installing a new bolt to hold it in place. I'm really in a pickle here, I've never had to do anything like this before.

 

[Curious Hound]

That's the way to fix it. It will be much easier once you get the manifold out of the truck.

 

[Bird76Mojo]

Pulling the exhaust manifold is the correct way to go about it if clearance is too tight to get to it, but that can also create more problems. You may break more bolts/studs removing the manifold. Then you've got bigger problems..

I'd try to remove the manifold, then possibly weld a nut to the broken stud to remove it. While it's still hot from welding, it should come out..

You might be able to get some vice grips on it, but heat the manifold as much as you can before turning on the broken stud. Get it cherry red hot if you can. Then try to turn it back and forth in small amounts, in both directions, until it frees up.

In the meantime, keep soaking both ends of the stud in PB Blaster or a similar penetrating oil.



GB

 

[adsm08]

Those and it will come right out.

I have never seen a 4.0 SOHC break exahaust studs in the head, it should be safe enough to remove the manifold and take it to an exhaust shop to have that broken one removed.

 

[sgtsandman]

I did what adsm08 suggests with the exception of not having the acetylene torch. I got by with using a propane torch and got the broken stud out. Installing the new one was a breeze.

 

[PetroleumJunkie412]

Trust the advice about doing it right. This is my leaking EGR plug that I tried to remove without heat. It snapped off at the manifold.

Then the manifold bung shattered when I put an extractor to it.

Then the exhaust manifold stud eyes on the head shattered when I tried to remove the manifold bolts without heat.