Stuck exhaust stud
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
Likes: 74
From: Blue Hill Township
Stuck exhaust stud
I am replacing the manifold studs/bolts/gaskets on the drivers side of the 2000 Expy. The bottom #8 nut had broken off and only the nuts came off on 3 other studs. 1 of the remaining studs came out with a 5mm? socket on the end of the stud. The upper #8 stud required the use of a stud remover. I picked up one from Sears for $25 or so and it puts the torque right on the stud rather than on the end and risk twisting it off. A little heat and the stud remover and you will be set. More to come later.
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
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From: Blue Hill Township
I buried half of my tap in the hole and said screw it. I put the truck back together still missing the #8 lower stud. I will pull the drivers side head off this spring and go visit a machine shop.
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
Likes: 74
From: Blue Hill Township
Thread Starter
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
Likes: 74
From: Blue Hill Township
I forgot to mention that I got absolutely owned on this thing. I tried welding a nut to the stud to turn it out and ended up just breaking off more of the last stud. I then ground it down and drilled it and when I was backing my tap off it got stuck and kept half of my 8x1.25 tap. I put it all back together except for the bottom #8 stud until later in the spring when I will tear the head off to take it in and have that hole fixed. 
Senior User
Joined: Aug 2001
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From: MA
Before pulling the head do some research on the internet. You still may have some options to get out the broken tap out. I had the same broken stud, ended up making a drilling jig, drilled out the broken stud and retapped the hole which took me about 5 hours and tons of patience and lots of threadcutting fluid. Prior to doing this I also researched my remaining options if the tap or a drill broke off as the last thing I wanted to do was pull the head.
Were you able to get the exhaust manifold and gaskets not to leak with that missing stud?
Were you able to get the exhaust manifold and gaskets not to leak with that missing stud?
New User
Joined: Jul 2008
Posts: 18
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I forgot to mention that I got absolutely owned on this thing. I tried welding a nut to the stud to turn it out and ended up just breaking off more of the last stud. I then ground it down and drilled it and when I was backing my tap off it got stuck and kept half of my 8x1.25 tap. I put it all back together except for the bottom #8 stud until later in the spring when I will tear the head off to take it in and have that hole fixed.
jg
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Fleet Owner
Joined: Mar 2003
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From: Blue Hill Township
The manifold was removed from the truck.
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Thread Starter
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
Likes: 74
From: Blue Hill Township
Before pulling the head do some research on the internet. You still may have some options to get out the broken tap out. I had the same broken stud, ended up making a drilling jig, drilled out the broken stud and retapped the hole which took me about 5 hours and tons of patience and lots of threadcutting fluid. Prior to doing this I also researched my remaining options if the tap or a drill broke off as the last thing I wanted to do was pull the head.
Were you able to get the exhaust manifold and gaskets not to leak with that missing stud?
Were you able to get the exhaust manifold and gaskets not to leak with that missing stud?
So far it doesn't seem to be leaking. We'll see how long that lasts...
