Exhaust studs size increase
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Cross-Country
Joined: Jul 2007
Posts: 73
Likes: 1
Exhaust studs size increase
I am having a bit of a problem getting a few of the exhaust studs out as they are pretty frozen in the head. I have 3 left on the drivers side to get out and all are corroded pretty bad. In fact I broke a #4 spiral easyout off in a drilled out stud today and it still didn't budge. I did finally get the easyout out but the stud seems welded into the head.
I do have it drilled completely through the stud lengthwise.
I was wondering about drilling it totally out and retapping with a larger size like a 9 or 10 mm since I will probably chew up the 8 mm threads if I have to drill these remaining b@@st@rds out. Seems like plenty of aluminum in theat area to go up a mm or two.
Anyone see a problem with this?
I do have it drilled completely through the stud lengthwise.
I was wondering about drilling it totally out and retapping with a larger size like a 9 or 10 mm since I will probably chew up the 8 mm threads if I have to drill these remaining b@@st@rds out. Seems like plenty of aluminum in theat area to go up a mm or two.
Anyone see a problem with this?
Elder User
Joined: Dec 2004
Posts: 675
Likes: 0
From: Springfield, OR
I know on the older cast iron heads if you drill only a 1/4 inch too deep you get into the water jacket, but i don't know if it's the same with the newer heads. As far as the width, I'd bet you could get away with drilling oversize once, maybe not twice, but your kinda in a situation where you need to do it anyway. This is a good question for a Ford engineer-or-if there's an old head on a wreck in a junkyard you could go and do a little experiment and see how it works.
Freshman User
Joined: Sep 2007
Posts: 32
Likes: 0
I ran into the samething on my v-10,I had 3 broke off and welded a bead to the studs and two of them turned right out with vise grips, the third one would not come out. I broke a easyout off in it, I chewed the head up pretty good trying to drill so much. There is plenty of room to drill bigger, what I did was got tired of messing with it and put it back together and put silicone around the port which was the back one, it doesn't leak at all, but put the manifold on and then drill enough for a 9 or 10 mm tap. With the manifold on you can keep the drill straighter as using the manifold as a guide. This will work and the 9 mm tap should work fine, but I have been driving mine everyday for 3 months and it still don't leak. That is just one stud though.
Hotshot
Joined: Mar 2007
Posts: 10,101
Likes: 40
From: Pa
Installing a Heli-coil is a common fix.
You may run with alignment issues when installing the manifold due to the larger stud.
When drilling center punch the stud, drill with a 60 deg. center drill (drill/c'sink) to help center the drill. Install a drill stop on the drill bit to keep from drilling too deep.
You may run with alignment issues when installing the manifold due to the larger stud.
When drilling center punch the stud, drill with a 60 deg. center drill (drill/c'sink) to help center the drill. Install a drill stop on the drill bit to keep from drilling too deep.
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AAubinoe
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Jun 13, 2015 08:29 AM
