Topic: removing broken exhaust studs from an ally head (Read 8564 times)

scrw · « **on:** March 03, 2015, 11:41:46 AM »

Any top tips?
2 out of 8 have commited suicide on the SAAB

, have a full stud and nut set coming, unsure if i should take the whole manifold off or just try to do the 2 broken ones through the mainfold.
Any suggestions on how not to fook up the head doing this would be appreciated

Off to buy some new drill bits and stud extractors first

bgbazz · « **Reply #1 on:** March 03, 2015, 05:35:50 PM »

If you have plenty of room to align the drill and get the centre of the broken studs (or very close to) you shouldn't have any problems with the manifold still in place.

Fingers crossed for you.

scrw · « **Reply #2 on:** March 03, 2015, 05:59:13 PM »

Quote from: bgbazz on March 03, 2015, 05:35:50 PM

If you have plenty of room to align the drill and get the centre of the broken studs

Had to buy a right angle drill attachment, bugger all room to line the drill up

bgbazz · « **Reply #3 on:** March 03, 2015, 07:46:02 PM »

Been there, done that...feel ya frustration! Get that manifold off and try again.

Dave69 · « **Reply #4 on:** March 03, 2015, 07:49:18 PM »

stop before you drill.

is there anything left of the stud and threads, if so can you get a double nut in place tighten the two together heat up the block then remove using the two nuts jammed together

yes the manifold will have to be removed, downside of shearing a stud.

drill and stud extractors can be dodgy especially when the extractor breaks since they are hardened steel

scrw · « **Reply #5 on:** March 03, 2015, 09:06:01 PM »

well its going shit. Turbo off (3h job) now the manifold won't come off due the power steering pump, which means engine mounts off & PS pump coming off to remove the mount for that. Both studs have broken off inside the head, common failure. You can't line the drill up at all as there is no room, best effort/guess to get it centred. I can see this ending with the head coming off, at which point I will contemplate scrapping the car, not worth the expense & hassle

scrw · « **Reply #6 on:** March 04, 2015, 10:05:39 AM »

4 hours of spannering I have the manifold off

now the horrible part

jay140285 · « **Reply #7 on:** March 04, 2015, 11:24:58 AM »

Good work so far in that case

scrw · « **Reply #8 on:** March 04, 2015, 11:29:00 AM »

Ah ha, I won

Both sheared below the head face, managed to get one with an extractor (amazed myself with that) other one was a drill out job. Found I was 2mm off centre drilling the stud so had the fun of tapping into alloy & steel at the same time, took about 30mins to get about 20mm into the head but it is sound and the manifold still fits okay (manifold holes are oversized to the stud size thank god)

Just waiting for the gasket to arrive at the local factors, I got a “manifold repair kit” from a Saab parts place, it contains all the studs, washers & nuts but no gasket, hey ho.

scrw · « **Reply #9 on:** March 04, 2015, 11:30:21 AM »

Oh and just for Jay, some 3" stainless, performance cat, turbo downpipe exhaust porn

jay140285 · « **Reply #10 on:** March 04, 2015, 02:35:38 PM »

I just did a wee!

bgbazz · « **Reply #11 on:** March 04, 2015, 04:49:59 PM »

Are you going to replace all the studs while you have the manifold off?....sorta makes sense to me.

scrw · « **Reply #12 on:** March 04, 2015, 06:32:32 PM »

I don't poke wasps nests

bgbazz · « **Reply #13 on:** March 04, 2015, 06:39:59 PM »

Quote from: scrw on March 04, 2015, 06:32:32 PM

I don't poke wasps nests

Might be the time to try it...they don't always sting!

scrw · « **Reply #14 on:** March 04, 2015, 06:43:23 PM »

The 2 at the other end which are a bitch to get at have already been replaced, only the 3 centre ones look old. I really don't want to faff about with them. Its the outer 4 that usually go and they have all been replaced now. Watch the middle one go now

I was that worried about them I even got my torque wrench out & did them up correctly!!

bgbazz · « **Reply #15 on:** March 04, 2015, 06:48:40 PM »

Sods Law always applies to me...bust my arse off getting it all sorted, tightning up the LAST one....POP!!! Back to square one.

scrw · « **Reply #16 on:** March 04, 2015, 10:18:01 PM »

well it all works

Its got a couple more notches on the warp factor now, remap next

jay140285 · « **Reply #17 on:** March 05, 2015, 08:07:15 AM »

Sweet, was it the 95 Aero you have like I had?

there is a guy in Nottingham on the Saab forums that's known for his mapping skills.

scrw · « **Reply #18 on:** March 05, 2015, 08:09:25 AM »

It is, off to see Karl next for some more warp factor

jay140285 · « **Reply #19 on:** March 05, 2015, 09:54:43 AM »

That's the chappy!!!

scrw · « **Reply #20 on:** March 05, 2015, 10:07:07 AM »

Cruising down to derby at the mo, at 80 leptons mpg is up fro 31 to 33, will pay for itself in 2 years lol

jay140285 · « **Reply #21 on:** March 05, 2015, 02:25:37 PM »

Yours Auto or Manual?

scrw · « **Reply #22 on:** March 05, 2015, 02:35:33 PM »

Author Topic: removing broken exhaust studs from an ally head (Read 8564 times)

jay140285

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jay140285

jay140285

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