Exhaust stud removal how i did it.
 

Hi guys i broke an exhaust stud taking off my headers. I was terrified at the ramifications of this. But i got it out and heres how i did it if anyone finds themselves in this predicament. This assumes that there is still some stud sticking out of the hole.

1) Spray with Pb Blaster for a few days.
2) Tap on it with a hammer
3) Get yourself some of these bolt/stud removers from O-reilly auto.
4) buy a propane torch
5) Heat the area around the stud with torch ( wear eye protection )
6) Spray some more pb blaster around it.
7) tap with hammer
8) repeat a few times
9) The last time dont spray pb blaster because i think it will cool the area.
10) Screw on the stud remover with Ratchet. Takes the 8mm.
11) carefully back it out. Mine came out like butter.

http://i213.photobucket.com/albums/c.../studtools.jpg

http://i213.photobucket.com/albums/c...studtools2.jpg

http://i213.photobucket.com/albums/c...brokenstud.jpg

http://i213.photobucket.com/albums/c...f/studhole.jpg

Good luck
JERRY

Cool! Thanks for sharing, I fear I will run into the same sooner or later...

You had the magic recipe, heat, impact, and juice.

And dont forget the coors light !!!!!!!!!

JERRY

That is great news! So from the pictures it looks like you used the smallest one in the pack, right?

What did you say was the total time it took from start to finish?
Thanks

After letting it soak for a few days Ed it took me about 8 to ten minutes for a few heat cycles and to get it out. Yes i used the smallest one in the pack i think it was 8mm.

JERRY

I have 2 remaining in there, 1 broken below the head, the other with .25 inches protruding after repeated ly welding nuts to it, heating for 10 minutes with mapp gas but still snapping off the studs.##

glad it worked for you, hoping for better luck tomorrow!

Is it required to remove these if not damaged? Mine have some rust on them but all but 2 stayed in the cylinder heads...should I replace all of them regardless?

Hey Buck i heard from a few people best to leave well enough alone. If you do break one off in the head you got some problems, nothing you couldnt overcome but you know...... Mine look tired and rusty as well and a couple even have a slight bow to them from heat i assume. If they all came out as easily as the one i broke i would do all of them. But it would still take a while and be a little risky.

JERRY

Leave them alone unless they are too short or already damaged.

Good to hear it. I only have 2 that need to be replaced then!

What happened to the pictures?

JohnJL, have you tried the left-handed drill bits and a reversing drill that has the hammer drill feature? I have found that this combination of tools is invaluable. I have been able to remove everything from broken exhaust studs/bolts up to sheared off head bolts. All of these have been below surface level. Just make sure the bits are good quality, and with the hammer drill on low speed, it pretty much zips them out. Be sure to use your favorite spray lube also.

Can you repost the pictures? For some reason it says that the photos have been removed or deleted.

Ok sorry pics are back!!

JERRY

Yes, I tried left-handed bits, easy outs (snapped 2), soaking, welding nuts, 15 minutes of MAPP gas, Loctite freeze-out spray, swearing at them, etc.

In the end my machinist couldnt get them out until he drilled them in a jig to a width of 7.85MM so that just the threads were left in.