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  #1  
Old 05-25-2010, 02:26 PM
Milwaukee Milwaukee is offline
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Location: Detroit, MI
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How to remove broke exhaust stud?

I know this is not truck repair but I thought lot people check this.


It 95 F250 with new 351W 19K miles ago it 5-6 years old.

It plow truck for 15 years.


We try replaced exhaust y pipe we finally remove but 4 studs stuck inside exhaust manifold. It stick about 1/2"


We been soak with kroil and Acetone with ATF nothing work.
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  #2  
Old 05-25-2010, 03:20 PM
Ruben Rocha Ruben Rocha is offline
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Unless you want to attempt to drill it out, then extract it with a easy out(not so easy) and or use use a helicoil I would suggest to take it to a machine shop and have them do it for you.
Even if you attempt it yourself. It is near impossible to do without a drill press so that means remove the manifold.
Or go to the junkyard and find a used one.

Last edited by Ruben Rocha; 05-25-2010 at 03:26 PM.
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  #3  
Old 05-25-2010, 04:50 PM
tennman tennman is offline
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As a last resort I would try soaking in PB blaster, heat, and a pair of vise grips if you could get a bite on that 1/2" sticking out.

You will most likely break off the nub, but as I said, it's a last resort effort.

Your best bet is like the last poster suggested, find a junk yard one.
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  #4  
Old 05-25-2010, 05:09 PM
poncho62 poncho62 is offline
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If there is 1/2" hanging out, weld a nut to it......Then, heat the area red hot and turn it out
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  #5  
Old 05-26-2010, 02:55 AM
Milwaukee Milwaukee is offline
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We been soak and torch to help loose thread inside.

We would leave truck for couple days.
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  #6  
Old 05-26-2010, 03:33 AM
topsites topsites is offline
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Remove the exhaust manifold?
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  #7  
Old 05-26-2010, 03:43 AM
Milwaukee Milwaukee is offline
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Quote:
Originally Posted by topsites View Post
Remove the exhaust manifold?
That be too big work

Not worth to do. We have plenty room.

We just soak exhaust stud where Y pipe hold mainfold.
Posted via Mobile Device
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  #8  
Old 05-27-2010, 03:28 PM
Ruben Rocha Ruben Rocha is offline
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Quote:
Originally Posted by Milwaukee View Post
That be too big work

Not worth to do. We have plenty room.

We just soak exhaust stud where Y pipe hold mainfold.
Posted via Mobile Device
There are three ways to fix this
Buy a new truck
Replace the manifold
Remove and repair the manifold.
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  #9  
Old 05-27-2010, 03:31 PM
Milwaukee Milwaukee is offline
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Location: Detroit, MI
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Broke studs end drill and tap.

Why I should get new truck this only have 19K miles on new engine.

Found egr pipe rot for long times. It been leak for long time. Tons of carbon on it.
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  #10  
Old 05-27-2010, 04:20 PM
Ruben Rocha Ruben Rocha is offline
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To remove a broken stud takes a lot of skill or luck if you need to drill it out and retap the hole.
You need to worry about how deep to drill. So you don't drill into the heads but deep enough to get to the bottom of the bolt
Also using a hand drill you have to keep the bit perfectly aligned with the broken bolt or you will need to retap the hole and use a helicoil. Let alone the drill bit drifting.
If you get it perfect then you will need a easy out tool to get what is left of the bolt.
If you have never tried to retap a hole in a cast iron part. You will find it is pure hell.
Let alone it is on the exhaust manifold so you will still need a torch to heat up what remains to get it out.
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