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Broken Exhaust stud REMOVEAL???

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Old 02-09-2006, 11:59 AM
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Default Broken Exhaust stud REMOVEAL???

I have an 86 slant in a D100 P/U
The #1 exhaust stud is broken in the head,recessed about 1/4" into the head!

What would be the best way to extract the broken stud??
 
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Old 02-11-2006, 04:00 PM
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Default RE: Broken Exhaust stud REMOVEAL???

It's not fun at all, but drill the center out and try an extractor bit. Soak the everloving hell out of it for a day or two with aerokroil or some other premium penetrating, rust-eating liquid. If that doesn't work, then you'll have to drill the hole out and either re-tap it for a larger stud, or try heli-coils. I know heli-coils work for spark plugs in aluminum heads, not sure about exhaust manifolds on iron heads though.
 
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Old 02-18-2006, 12:14 PM
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Default RE: Broken Exhaust stud REMOVEAL???


ORIGINAL: horatio102

It's not fun at all, but drill the center out and try an extractor bit. Soak the everloving hell out of it for a day or two with aerokroil or some other premium penetrating, rust-eating liquid. If that doesn't work, then you'll have to drill the hole out and either re-tap it for a larger stud, or try heli-coils. I know heli-coils work for spark plugs in aluminum heads, not sure about exhaust manifolds on iron heads though.

Thanx for the info!!!

It took 2 of us about 1- 12 packof Beer,10-12 different size drill bits and about 4 hours,BUT,we got it out and re-tapped and it seems to hold fine!!
 
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Old 02-18-2006, 03:13 PM
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Default RE: Broken Exhaust stud REMOVEAL???

Cool. Sounds miserable. The third option I forgot to mention, and the most expensive, is to take it to a machine shop and pay somebody else to muck with it.
 



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