Broken exhaust manifold stud.
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Postmaster
Joined: Jun 2001
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From: Loveland, CO.
Broken exhaust manifold stud.
It seems as if the very last exhaust manifold stud (towards the cab) on the passenger side decided to break off by itself. One day it was there, the next day I had an exhaust leak and a missing nut with a hole and a broken stud inside of it. This is going to be very hard to fix on the truck, I can hardly even see it much less get in there. Even my shop is hesitant to mess with it, but they said that they would do it. The worst case scenario is that we get the manifold off, and the stud is broken off flush with the head. There really is not much room to work in there. I'm wondering if the leak is coming out from the bolt hole, or the gasket because it's a little loose now, or both. Is there anything that I can put on there that can withstand manifold heat, just to shut it up? Why can't my Bronco just have NORMAL problems???
Senior User
Joined: Oct 2002
Posts: 189
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From: Texas A&M
Broken exhaust manifold stud.
it can't leak out of the bolt hole. the hole is to the side of the exhaust port. it must be leaking around the gasket to the hole and out that way.
the left (passenger) side manifold is definitely doable though. the toughest part is removing the manifold from the y-pipe because of room reasons. with a good long socket wrench and a cheater bar you can get to the back bolt easily. its really isn't all that painful - you could probably do the manifold on a saturday. and you might not even have to unbolt it from the y-pipe, so that saves some time as well. just be sure to remember how the external brackets (for lifting the engine), the little rod from the ground on the intake manifold, and the heat shield bolt back onto the manifold. and when you label your spark plug wires, label them before you pull them out so you dont switch the 7th and 8th cylinder and freak yourself out when the truck backfires and runs super duper rough. (recent experience.)
if you have any questions i'd be glad to help out, i just swapped mine out this weekend.
the left (passenger) side manifold is definitely doable though. the toughest part is removing the manifold from the y-pipe because of room reasons. with a good long socket wrench and a cheater bar you can get to the back bolt easily. its really isn't all that painful - you could probably do the manifold on a saturday. and you might not even have to unbolt it from the y-pipe, so that saves some time as well. just be sure to remember how the external brackets (for lifting the engine), the little rod from the ground on the intake manifold, and the heat shield bolt back onto the manifold. and when you label your spark plug wires, label them before you pull them out so you dont switch the 7th and 8th cylinder and freak yourself out when the truck backfires and runs super duper rough. (recent experience.)
if you have any questions i'd be glad to help out, i just swapped mine out this weekend.
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Postmaster
Joined: Jun 2001
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From: Loveland, CO.
Broken exhaust manifold stud.
I'm not worried about the y-pipe (do you mean where the donut is?) I already had a socket on those bolts to tighten them before I saw the broken stud. It just took a long extension, wasn't too bad. But I can't even see all the manifold bolts, much less get a wrench on them. I'll have to take another look. Maybe I can determine how much of the stud is left in there by sticking something inside the hole before taking the manifold off.
Senior User
Joined: Jul 2002
Posts: 234
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From: mpls Usa
Broken exhaust manifold stud.
if you do get the y pipe off and find the stud has a little of it sticking out,I saw an ad tonite for a new tool from craftsman (sears) called bolt out or somrehting to that extent that may help back the bugger out. I think the set was about 20.00.
I hope this helps, let us know......
Craterjoe
I hope this helps, let us know......
Craterjoe
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Postmaster
Joined: Jun 2001
Posts: 2,809
Likes: 3
From: Loveland, CO.
Broken exhaust manifold stud.
Yeah, I saw that on TV but forgot about it. That is a very good idea. Thanks. I hope the stud is not broken off flush with the manifold, or is seized.
New User
Joined: Mar 2003
Posts: 2
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From: Saskatoon
Broken exhaust manifold stud.
Funny thing - just replaced the studs and bolts etc on mine -1990 302ci. The Driver's side rear most stud was snapped from previous owner..
I drilled a 5/32" pilot hole and once the drill passed the end of the bolt - lucky break - pun almost intended -
and squirted some releaseall into the hole - sat for an hour and out she came with a bolt extractor.
This was all done with engine in - cramped but doable -
bought a Fel-Pro gasket set for the beast - and the problem is they don't seem to fit...??? anyone possibly know why?
The part number is MS90000 and says it is supposed to fit the 302 for the year of the engine. HELP...
thanks
I drilled a 5/32" pilot hole and once the drill passed the end of the bolt - lucky break - pun almost intended -
and squirted some releaseall into the hole - sat for an hour and out she came with a bolt extractor.This was all done with engine in - cramped but doable -
bought a Fel-Pro gasket set for the beast - and the problem is they don't seem to fit...??? anyone possibly know why?
The part number is MS90000 and says it is supposed to fit the 302 for the year of the engine. HELP...
thanks
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