Impossible bolts broken stud

[oya]

Hi everyone just looking for some advice. I need to replace a busted y pipe. I broke a stud on the manifold. I think collector stud. These bolts look impossible to remove. I'm thinking about welding a nut onto there upside down with the manifold still attached. Any thoughts? I used a fiber fix patch to get where I was going, 2 of them. It worked better than i thought, but it too failed after about 45 minutes.

 

[Pin_Head]

Welding a nut on the broken stud usually works, but the Y pipe looks like junk. Not enough metal left to weld. It might be easier to remove the manifold first.

 

[Proven]

This could be an unpopular opinion, but I would plan on replacement of headers, studs and Y pipe.

 

[BILT4ME]

Try the welded nut thing first.

Then drill it out, heat with torch, cool with PB Blaster about 10 times. Get the stud red hot each time, then use an easy out.

It would a lot easier to do if the manifold was off the truck. But, I get it.

 

[Rifleman]

In all my years of turning wrench's on cars, I've never been able to understand why only a few car manufactures install brass nuts, bolts, and studs on their exhaust systems. Working on cars that have brass hardware installed makes it a breeze to remove a rusty exhaust manifold, even if that exhaust manifold has been on the car for 10 or 20 years.

 

[BILT4ME]

In all my years of turning wrench's on cars, I've never been able to understand why only a few car manufactures install brass nuts, bolts, and studs on their exhaust systems. Working on cars that have brass hardware installed makes it a breeze to remove a rusty exhaust manifold, even if that exhaust manifold has been on the car for 10 or 20 years.

Yup!

I double brass nut the studs on the manifolds of my Studebaker!

 

[fjbj40]

I would remove the manifold, try it yourself, but you better have oxy/acetylene or it ain’t happening! Or, get a machine shop to remove the broken piece and the remaining intact one. They take a lot of work to remove, I just did two and they were my worst experience in removing exhaust studs yet!
Install all new hardware for the manifold in the head and where the pipe hooks up. The hardware from Toyota is not very expensive

 

[Pin_Head]

My experience is it doesn’t matter what you weld it with, but you need to heat it hot enough that the stud gets red hot through the hole so that the stud shrinks as the metal cools. Then they come out easy. It might take more than 1 try, but they all come out.

 

[bigredmachine]

lots of heat, lots of soaking with whatever magic spray you prefer and a stud puller similar to this Wilmar Stud Puller 4 Piece, SAE | Northern Tool + Equipment.

 

[oya]

plan is to replace the y pipe, we are avoiding the manifold moves, so will try welding a nut first. thank you, will update here!

 

[oya]

Amazon product ASIN B00ATSL7VE
Does anybody have any input on this product? Do you think it worths the $ ?

 

[BILT4ME]

Amazon product ASIN B00ATSL7VE
Does anybody have any input on this product? Do you think it worths the $ ?

Someone posted a thread about a similar tool in the "Tools" thread.

 

[Mark W]

Removing the manifold from the head is not a big deal. A lot easier than trying to deal with the broken stud in situ.


Mark...