Engine/Transmission (1998.5 - 2002) Help - Broken Manifold/Stud

[rblomquist]

Guys,



In the process of putting in some new gaskets I noticed the exhaust manifold was cracked along the bottom center. Well in the process of putting it back together I snapped off one of the studs There's about 2. 5 threads left outside the surface of the head.



I have about 2 months left on the warranty so I'm hoping DC will go good for the manifold.



I can't decide whether it would be in my best interest to try to get the stud out somehow (suggestions appreciated) and replaced with a new one before I go to the dealer or if I should leave it and give them the opportunity to fix it for me. What I'm afraid of is if I walk in with a snapped off stud they might say the manifold cracked because I over tightened it.



I've never extracted a bolt like this and as such I don't have any ez-outs on hand nor do I have any taps. I'm a little nervous about doing it and screwing it up worse however, I really need DC to buy the new manifold (not me).



Thanks in advance.



What do you guys think?

 

[csevers]

If you chose to try to remove the broken off stud and you have a welder here is how i would do it: Spot weld a flat washer(the right size for the stud) to the stud then take a nut 4 times bigger or so and put it over the stud and washer and weld the nut full and to the washer/stud and wait till it is cool and remove. You may have to try a couple of times to get a good weld to the stud but the heat of welding really helps things come loose. I only drill and ez out/retap things as a last resort.



DC shouldn't fight the new manifold they should know that they shrink up and break off manifold bolts all the time.



Good Luck

Craig

 

[Sticks]

Another option is if there is enough threads showing, buy a stud puller. The type that looks like a deep well socket works best.

 

[jkeyes]

I have an ATS 3 pc for sale so this doesn't happen again, if you are intetrested.



Jason

 

[rblomquist]

Originally posted by jkeyes

I have an ATS 3 pc for sale so this doesn't happen again, if you are intetrested.



Jason

I've PM'd you.