2000 excursion, 4X4, V10


After 7 days in my garage, I finally removed/replaced all 20 manifold studs. I had to cut off all of the nuts to remove the manifolds. I was able to remove 17 out of 20 studs by using a 6 inch pipe wrench and a lot of coaxing. 3 of the studs were already snapped off inside the head. I drilled out two and was able to get them tapped for a Heli-coil. The third stud I broke a 1/8" cobalt drill bit inside and it took 4 days to get enough of the hole drilled out to get a Heli-coil inserted. I read all of the postings on this site regarding this job and the information was very helpful. Thanks to all that posted very valuable information.


Robert

 

Congratulations! It's an undertaking but you saved a ton of $$ and know it's done correctly.

 

I think this demonstrates more patience than I am capable of producing. Good job, man!

 

Wow, that's patience.

 

They are brutal, I am glad I only had 16 to do and not 20..

 

Man I have this coming real soon and seeing seven days down made me hang my head

 

If you can get access to a MIG welder, even a 110 volt unit like mine it will make the job somewhat easier. I only had 2 broken studs got one out by welding a nut unto it, the other I had to left hand drill out and pulled it with an easy out.
Broken studs are a great excuse to install headers!

 

Why left hand?

 

Are you guys doing this with manifolds on or off?

 

lefty loosey, righty tighty.

 

Hoping the bit will spin it out?

 

Hoping is right!

 

As it so often does.

 

Yep Brent, left handed bits so IF it catches and grabs the stud MAY spin out. Didn't make a difference for the one stud I drilled, it stayed put until I got a decent bite in it with an easy-out.

And I just forced a socket on the corroded nuts on the surviving 18 studs, they all spun completely out without any breaking. I was swapping the stock manifolds for headers so the manifolds came completely off to work on the two broken studs. Makes the job easier in my opinion because with the logs off you can actually see the stud stub that you are working on.

 

Ya me either. On the 4 studs that I drilled out completely, I used a "lefty" about every third bit but never got any love. If it's not coming out with an easy out and its below flush it's either welding (which is not on my skills list) or drill baby drill.


Anyone doing this DIY should have back up transportation in place for at least 5 days. Some can get away with just a day down, but have heard and lived through one horror story of my own. Believe mine was down about 20 days but that also included some axle work, full exhaust including the CAT.