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Hooch252

Exhaust Manifold Studs

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What can I use to break free my exhaust manifold studs?

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On 7/17/2019 at 8:30 PM, Hooch252 said:

What can I use to break free my exhaust manifold studs?

 

5.4L Triton? I did a manifold job on my Dads 2002 F250 4X4. I got lucky that on that application, I took the shock and upper shock mount off and the manifold was right there. An old time shade tree mechanic told me the easiest way to remove the manifold (two manifold bolt heads had broken off, hence the famous exhaust leak) was to just cut the rest of the heads off the remaining manifold bolts and then slide the manifold off. I was able to grip the bolt shafts with a vice grip and spun the bolts right out except the one that broke off under the flange and needed to be drilled out. But, end of the day....it went back together and all was well...

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These work great to remove broken studs

 

https://www.amazon.com/dp/B001A4CWHO/ref=cm_sw_r_other_apa_i_x7WYEbZ0WJM4D

 

Or these reverse bits.

 

Check this out at Amazon.com
IRWIN Screw Extractor/ Drill Bit Set, 35-Piece (11135ZR) https://www.amazon.com/dp/B000EEX644/ref=cm_sw_r_other_apa_i_18WYEb2J9YAF8

 

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The ones that are not rotted too bad, take out with a socket. The stud usually comes with.

 

The ones that the nuts are rotted on, best to use a "twist" socket:  https://www.amazon.com/Ken-Tool-30109-13-Piece-Twist-Socket/dp/B00C3IFM5K If you can't get them off, like Twintornados said, use a blue wrench, but then you have to wait for them to cool which EATS time. 

 

Broken studs that are above the surface use a small twist socket if it will bite OR a stud remover like these:  http://corporate.cornwelltools.com/webcat/products/CBS4MSRIS-%2d-4-Piece-Metric-Stud-R%2d-I-Set.html

 

IF they are broken off below the surface, a MIG or TIG to weld a nut/washer on is easiest and fastest. Drilling takes WAAAAY too long, goes through bits like mad, hard to access and generally SUCKS. I have seen a lot of shadetrees hit coolant passages trying to DIY, or had to helicoil when the drill got off of center, or worst of all, broke extractor off in stud, which is a whole new level of "OH $#!+!!!".

 

If you feel you JUST GOTTA drill them,  https://www.lislecorp.com/specialty-tools/manifold-drill-template-ford

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