EGR Stud Woes

[MJM]

I little history on my 83FJ60 when purchased many years ago the stud holding the EGR pipe to the exhaust manifold was broken. I was able to drill it out and cut in new threads, I used that BS kevlar (paper) gasket instead of OEM. A cuople years go by and I am sick of the leak so I went to put in the OEM and just when I went with the last turn of the socket (we all know what a PITA this is) the bolt broke. This was on the repaired side.

What are my options.

RE-Tap : Good way to go but may no work b/c of limited space and that fact that the broken bolt is in there.

Remove it: Can you weld a cap on that sucker while in place (no smog in my area and I do not care about resale) De smog the whole truck. I do the heat riser I had a cruiser with headers and winter warm-up were no fun.

Repalce it: I already have that one side of the manifold: can you just replace one section of the manifold( I think it will leak at another location if I try that.


BTW this broken bolt pissed me off big time.

Thanks
MJM

 

[brian]

at this point, take the manifold off.
you already 'fixed' it once.

you could do a better repair on the bench.

the manifold is three pcs, but if iirc the erg comes off the large middle pc, which is most of the manifold anyway. but if you take it off, the gaskets one the little end 'ears' will probably blow out.

i'd say header at this point. smog is not in question so have at it.

 

[MJM]

All Fixed for Now

I went the short route and drilled out the broken bolt then ran a tap in and made some new threads. I did the hela coil last time and was not pleased with the result. The OEM gasket is the way to go. I did this under the truck what a PITA but less time than a full manifold removal. It is nice to have a truck without the exhaust leak.