Engine/Transmission (1998.5 - 2002) turbo to ATS 3pc manifold bolts

[Pavemen]

Bought my truck used many years ago and its got a stock turbo on a 3pc ATS exhaust manifold and the other week one of the upper bolt heads snapped off.



I noticed a bit of carbon buildup at the joint there and took a wrench to the bolt and barely had to move it to break the bolt head off the rest of the way. It had been cracked for a while as there was rust on the fracture surface.



Are those bolts and studs special at all or does the ATS setup just reuse the factory bolts? I sent a note to ATS but they have not replied yet.

 

[monkeyman]

One of mine feel out, they are Metric, I forgot size, ATS will tell you if you call. I used a stainless one. I have to pull my head when it gets warmer, I am going to use the locking bolts on the manifold when I do
Rick

 

[Joseph Donnelly]

stock studs are M10 x 1. 5 thread

 

[JMcCoy]

Ats had me reuse the rusty old manifold-to-turbo studs and nuts. BS if you ask me.

 

[Pavemen]

so the stock setup uses all studs? wonder why my truck was converted to bolts on top. simplicity I assume

 

[JMcCoy]

It was probably easier than removing the studs from the old manifold, or they were damaged during removal.



Were you able to remove the rest of the bolt, or will you have to drill and tap it?

 

[Pavemen]

i have not tried pulling the rest of the bolt yet. i will probably work on it this tonight or tomorrow

 

[Pavemen]

well the left over bolt came out pretty easily. getting to it sucked though.

unbolted the bank exhaust brake from the elbow, pulled the lower intake tube, removed the exhaust elbow bolts, removed the remaining turbo top bolt and pulled the two lower nuts on the studs.

was able to slide the turbo enough to get a set of needle nose vise grips in there and turn the shank and unthread it.

put it all back together but am ticked off and how mixed SAE and metric the parts are and the limited space for my big hands and arms. getting the lower nuts off the turbo was a PITA.

 

[Joseph Donnelly]

Dodge/Cummins went to bolts on the top two positions around the time the 24 valve came out. I don't recall if any 24v engines used 4 studs.