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How to remove broke exhaust stud?

Discussion in 'Mechanic and Repair' started by Milwaukee, May 25, 2010.

  1. Milwaukee

    Milwaukee LawnSite Member
    Messages: 144

    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.
  2. Ruben Rocha

    Ruben Rocha LawnSite Senior Member
    Messages: 577

    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: May 25, 2010
  3. tennman

    tennman LawnSite Member
    Messages: 32

    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.
  4. poncho62

    poncho62 LawnSite Member
    Messages: 222

    If there is 1/2" hanging out, weld a nut to it......Then, heat the area red hot and turn it out
  5. Milwaukee

    Milwaukee LawnSite Member
    Messages: 144

    We been soak and torch to help loose thread inside.

    We would leave truck for couple days.
  6. topsites

    topsites LawnSite Fanatic
    Messages: 21,653

    Remove the exhaust manifold?
  7. Milwaukee

    Milwaukee LawnSite Member
    Messages: 144

    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
  8. Ruben Rocha

    Ruben Rocha LawnSite Senior Member
    Messages: 577

    There are three ways to fix this
    Buy a new truck
    Replace the manifold
    Remove and repair the manifold.
  9. Milwaukee

    Milwaukee LawnSite Member
    Messages: 144

    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.
  10. Ruben Rocha

    Ruben Rocha LawnSite Senior Member
    Messages: 577

    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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