Broken exhaust manifold stud. HELP

[skwerl]

Yesterday I began my transmission swap to install a used 3650 after a local shop ruined mine. I wasn't willing to let them touch my car again after finding numerous stripped bolts, everything was tightened with an impact gun, broken and missing parts, etc. It was really bad.

The driver's side exhaust was overtorqued to the point where the nuts stripped when removing the exhaust. One of them I was able to remove and replace, but the other one went south on me. First all the threads stripped off so I had to use my Dremel to cut off the nut. Once the nut was off I couldn't get the stud out. I heated the manifold and hit the stud with ice and that didn't work. I borrowed a stud extractor and that just sheared off the rest of the threads. I used the Dremel to cut flat sides in the collar so I could grab it with Vise Grips and that didn't work. So I cut the stud off flush so I could drill it out. No problem, I have 3 sets of drill bits as well as the correct size tap to clean up the threads. I got a 1/8" hole drilled through but when I stepped up to the next size the bit snapped off in the stud. I can't get anything in from above to punch the broken drill bit out due to the curve of the manifold.

Now what do I do? Do I have any other options than to remove and replace the manifold? I'm not sure if I can get to all the fasteners without disassembling half the engine.

 

[skwerl]

OK, what all do I need to remove in order to remove the driver's side exhaust manifold? Lots of guys here have done headers in their garage.

 

[Captainstr8edge]

I did the same thing. I was using one side for a little while, then I made a makeshift clamp. Then when my motor went I got another set locally cheap. My dad owns a metal fab shop and they couldn't get it out, so your best bet is to do a swap. Might as well get long tubes since your going to be doing the work anyways.

 

[skwerl]

I found a diamond bit in my Dremel case and that seems to be making some headway. Now my battery is dead so I need to wait about 30-40 minutes for that to charge up again.

Looking at it a bit closer in case I still need to remove it, looks like I can block up the motor and remove the motor mount bracket and the steering shaft and get all 8 manifold nuts from underneath. Thankfully my BMR K member gives me quite a bit of access.

 

[fdjizm]

That's going to be rough, I'd say try to drill it out completely ruin the threads then use a regular long bolt to put it back together instead of a new stud. or throw that shit out and get a replacement!

 

[Swarzkopf]

That's going to be rough, I'd say try to drill it out completely ruin the threads then use a regular long bolt to put it back together instead of a new stud. or throw that shit out and get a replacement!

This. The right drill bit will power through that.

What kind of drill do you have? A good drill helps, too. My 8 amp DeWalt gets through just about anything.

 

[skwerl]

That was an excellent suggestion! My Dremel wasn't charging up quickly enough so I put the diamond bit in my Makita 18v cordless drill and got around the broken drill bit. Then I drilled it out big enough to throw another bolt in there. It's not pretty but it's on!

 

[white05gt]

I just saw this and even though it's too late, a welder and penetrating oil would have taken it out with no problems. I would have welded a washer to bolt then welded a nut to the bolt/washer then cool it down spraying with a good penetrating oil. Once it's cool to the touch you can take a wrench and back it right out almost every time.

 

[fdjizm]

Good stuff that will definitely hold bro! it's just a clamp so that's all it needs anyway.

 

[AnotherS197GT]

I have a set of manifolds sitting in my garage. If you want to replace that one let me know and I'll send them to you for the cost of shipping.

 

[BruceH]

You have willpower. I would of seen that as a sign to put headers on.

 

[skwerl]

Bruce, I'm not seeing a lot of advantages to headers. The stock manifolds are pretty open and with the cat delete pipes there isn't much resistance. On the other hand, headers would make other tasks much more difficult. This is a used transmission I just installed and the clutch is just an off-the-shelf brand so the likelihood of me having to go back in within the next year is high. Headers would need to come off to do that.

At some point I would love a T56 but it's simply not in the budget right now.

 

[Turbostangs90]

On a side note, are the stock manifold gaskets reusable? Or should they be replaced?

 

[one eyed willy]

On a side note, are the stock manifold gaskets reusable? Or should they be replaced?

Reusable!

 

[Turbostangs90]

Let me clarify this....exhaust manifold gaskets....not intake gaskets.

 

[one eyed willy]

Let me clarify this....exhaust manifold gaskets....not intake gaskets.

Yes, MLS manifold gaskets between the head and exhaust manifold....reusable!

 

[Mustang30212]

You don't have to remove headers to pull a 3650....ask me how I know THIS! haha

RH