Bolt To Exhaust Manifold Snapped!

[recce]

Hi all! What a bad start of the new year. I try to tighten the nuts to the exhaust manifold (as it is making nosie when turbo kicks in as well as it was loose) and it snapped at the engine block. What can I do now! Who can I go to to get it repair? Hope that will not cost a lot of $$$$. Please help!

[Sinista32]

I think you need to use a tap and die set on it. Try Greg at Pro Eng. Certain it happens all the time in engine shops. I really dont think it'd cost much at all. Labour component only and if you got a socket on it to snap it off then it wouldnt be too hard to get too.

[widebody32]

Depends which stud it is, sometimes you can get a drill and an easy out in situ but if it is not accessible then you will have to pull the manifold off. If you want to have a go at removing the stud yourself, i can lend you the stuff to do it and give you advice.

[tridentt150v]

You'll likely need to remove the manifold [and turbo, dump, water lines, oil lines, intake pipe etc] about two hours work. Then you have to remove the manifold. Use heaps of CRC/WD40 on all the nuts and studs.

Once you have the manifold off [and you could snap a couple more studs doing it yet], see if you can get vise grips etc on the protruding part of the stud and reomve it. If it is too short to do this, then you can try welding a nut onto the end of the stud and then remove it while still warm just like a bolt. If the stud is snapped off at the block then you have to be very careful and drill a hole in the stud and then use an ezi out [this is a mongrel act, plenty of cursing and skun knuckles, but be very careful and patient]. Hopefully all this will work, if you snick the thread while your drilling, you may need to use a tap to clean up the thread before you replace the stud. When replacing the studs {I'd replace all the manifold studs, buy a kit], nuts, and bolts etc use nickel or copper cote antiseize compound. Use a new stud and gasket set/s for all the job. Also get the good studs, there are cheap ones out there that you should avoid.

Cost, around $150-$200.

Too easy isn't it!!!!

Or you could take it to a shop and they'll do the job for around $500 or more.

[recce]

Thanks for all the advise. The stud that got snapped was the very first TOP one closest to the fan. I really don't want to pull out the manifold and create more problems. I think the best will be driving to a work shop to get it done. If it is too expensive at the shop then I'll DIY. Cheers!

[Scooby]

You could try and find someone who does spark erosion. I'm pretty sure I saw a van the other day that advertised it. It's a process where an electrode is used to erode the stud away, followed by running a tap through the hole to clean up the thread. Useful for situations where an easy out is not going to work.

Cheers

[widebody32]

If its the one at the front then it shouldn't be too hard to do in car. There is a Mobile guy called capital thread repair that could come to you.

[StinkyPoo]

Yep, capital thread repair. I forget his name, but he has done my mates car. Does mates rates if you got a mate that knows him. Cost us $60 to remove a snapped Harmonic Balancer bolt. I think its a per bolt basistoo