Question about 2003 Triumph Speedmaster

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Two exhaust manifold studs have rusted and broken off (2001 Honda Accord 4 cyl). Can the be drilled out an replaced with oversize studs ?

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  • Dave Yarborough Oct 03, 2010

    thanks jj, sounds right !

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Posted on Oct 04, 2010

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You can get an easy out tool from Auto Zone which will let you drill them out and remove the pieces and then re-thread the hole or drill them and put boss inserts in to replace them with the same size studs. These Easy out tools usually come with a drill bit and threader tool and run about $12.00

Posted on Oct 03, 2010

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1 Answer

Exhaust manifold bolt broke off into head, is there anything I can use to temporary fix it.


no temporary fix
the real fix is to remove the manifold , drill and use an extractor tool to remove the broken stud
however if the stud is at the end of the manifold , consider this
many exhaust manifolds do not use a stud at the ends

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I have a 2003 Ford Ranger 3.0 and I have an exhaust manifold bolt that has broken off inside the manifold,and the evaporator coil,and other AC parts are in the way .what options do i have on this


With the exhaust manifold off. If there is some of the bolt sticking out. You'll need a torch to heat the head up, red hot around the bolt. Also a pair of needle nose vise grips to grab it with and turn it out. You'll have to heat it several times to get out. No bolt showing, you best bet it to pull the head. Drill the bolt and extract it.

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1 Answer

If I break the rear stud on a 318 manifold head bolt in the rear or front stud and if I drill it out and see antifreeze come out have drilled through the water jacket or is it open to the block


It is very rare to through holes to the water jacket, especially the holes of fairly important studs and bolts. It happens mostly in die cast items such as some cylinder blocks and some holes to the oily parts are through and also some to where there is air or exhaust gas on the other side.

There is no need to despair yet even if you have drilled off course or simply gone too far. There are ways around such problems if indeed it is a problem and you won't know until you have removed the manifold and taken a close look.

There are repair epoxies and putties of various types intended to reclaim such errors and there are specialist cold stitching techniques which can reclaim almost anything made of metal. For areas that must be strong and are subjected to very high temperatures I drill and tap oversize and sometimes make a double diameter stud and sometimes I plug the oversized hole with a large bolt and machinery adhesive, cut off flush and re-drill and tap the original size.
Good luck!

Feb 06, 2015 | Cars & Trucks

1 Answer

How to remove the oil pan on a 1996 honda accord


First you must remove the A exhaust pipe that is under the oil pan. Make sure use a penetrating lube, like WD-40 on all exhaust nuts. If there is a lot of rust, you can remove the 3 or 4 manifold nuts, the 2 bolts for the bracket to the block, and unhook the exhaust hangers, and move the whole exhaust out of the way. Drain the oil, then remove the support brackets, then all the 10mm oil pan bolts and nuts. The oil pan can seem glued in place, pry it loose without bending it. Make sure you get any steel rings off from around the studs, they are part of the oil pan gasket, and tend to stick to the block.

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1 Answer

EXHAUST MANIFOLD CRACKED OR BLOWN GASKET


Big issue with these is the exhaust manifold bolts/nuts rusting off. if you are lucky you can get the partial stud out of head if not they need to be extracted either in truck or heads off and extracted/drilled and re-taped.. not a plesant job

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1 Answer

Studs for a exhaust manifold rusted off flush with the head. I tried drilling a giude hole for easy outs but the drill bits walked off the center of the studs. The bit chewed into the head and made a hole...


If you have a welder and a torch set you can still get them out. take a 3/8 nut put it over the broken bolt and weld it together. then take the torch and heat the nut and head up. you need to heat these up to a glowing red. then start removing the bolt. go back and forth if you have to. good luck. ps if you don't have the tools remove the head and take it to a shop

Jun 18, 2010 | Cars & Trucks

1 Answer

Broken manifold bolts / manifold removal


Whatever it takes, but make sure you soak some penetrating oil oi wd40 on others to avoid any more being broken. Pulling the manifold is the safest and quickest way. With it out of the way, you'll have someting on the broken bots, now studs to work with. Always drill a broken stud or bolt clean through. Penetrating oil can work from both ends and a broken easy out can be driven in far enough to work arounf -Good Luck, force nothing, Tap stud and apply only stesdy even presure when extracting.

May 19, 2009 | 1999 Ford F150 Regular Cab

1 Answer

Exaust manifold replacement


Stud removal can be either very hard or easy. Just depends on how hard access is to the stud. You will need to center punch the broken stud. Then use a very good high speed steel drill bit to drill a pilot hole in to the stud. Tap an easy out in to the hole you drilled into the stud and hopefully it will break loose. Worse case scenario is you might have to remove the head and use a torch to heat it for removal or actually use the torch to blow it out of the hole. If you must remove the head and need to use a torch to remove the stud send the head out to a good machine shop. These shops have people there that are qualified to do this process. To much heat can damage the threads in the hole or ruin the head. Good luck. If you ahve more questions please feel free to ask.

Mar 05, 2009 | 2001 Ford F250 Super Duty Super Cab

1 Answer

5.4 liter Triton motor


you have leaking exhaust manifolds.the 5.4 is very well known for exhaust manifold studs breaking.i have drilled out hundreds of broken studs.

Oct 22, 2008 | 2000 Ford F250 Super Duty Crew Cabs

1 Answer

Engine problem


These 3.0 engines had an issue with the manifolds warping and shearing off the manifold studs particularily on the corners. To repair correctly you would need to replace the warped manifold with new and drill ad possibly tap out broken studs and replace all studs with new. The only problem I am having with your question is that usually the exhaust smell lessens when the engine gets hotter as the expansion causes some sealing. But anyways thi is most likely your issue.

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