Triple Nut Exhaust/Sport header removal 1977 911

[BCLi]

Hi all:
I'm in the midst of pulling apart my recently acquired '77 911 2.7l engine in order to fix the myriad of leaks and update. Upon looking at my heat exchanger-less exhaust, there aren't the usual nuts, but a pile of three (see figure). As is usual, I really want to avoid breaking studs, so I ask for the collective wisdom of the group - what's the best way to address this triple threat? One nut at a time after PB Blaster/Liquid Wrench?

Thanks,
Bert

[30westrob]

I believe you only have one nut, holding two larger nuts as spacers. After the end nut is off, the two spacer nuts will come right off. Rob

[otto_kretschmer]

You have the long studs like I do. Just take the nuts off and be careful. I don't think you will have a problem. They look in better shape than mine are.

https://forums.pelicanparts.com/911-engine-rebuilding-forum/1080368-exhaust-studs.html

[Flat6pac]

Originally, the 77 had thermal reactors. The thermals used long studs for thick flanges
The studs are narrower between the threads so don’t tighten to break loose.
Bruce

[BCLi]

Originally Posted by 30westrob

I believe you only have one nut, holding two larger nuts as spacers. After the end nut is off, the two spacer nuts will come right off. Rob

Thanks - I will look more closely at all of these to see. Much appreciated!

[BCLi]

Originally Posted by otto_kretschmer

You have the long studs like I do. Just take the nuts off and be careful. I don't think you will have a problem. They look in better shape than mine are.

https://forums.pelicanparts.com/911-engine-rebuilding-forum/1080368-exhaust-studs.html

Thanks Otto - good to have your experience here. Thanks for the link to your post - I'm sorry I missed it; didn't come up on my search. Very helpful.

[BCLi]

Originally Posted by Flat6pac

Originally, the 77 had thermal reactors. The thermals used long studs for thick flanges
The studs are narrower between the threads so don’t tighten to break loose.
Bruce

Thanks Bruce - as usual, your knowledge is incredibly helpful. My hope is the magic of penetrating fluid might be able to help me get these off with nary a broken stud (and no tightening to break loose!).

[yelcab1]

Good God. Now I have seen it all.

[911pcars]

Just to confirm the basics, use a box wrench or 6 pt. socket to avoid rounding the hex corners. You might want to use another wrench on that "spacer" nut to provide additional structural support as you attempt removal. You want to take all steps to avoid breaking said stud.

Sherwood

[BCLi]

Originally Posted by 911pcars

Just to confirm the basics, use a box wrench or 6 pt. socket to avoid rounding the hex corners. You might want to use another wrench on that "spacer" nut to provide additional structural support as you attempt removal. You want to take all steps to avoid breaking said stud.

Sherwood

Thanks Sherwood - that's a great idea. I was going to use a T-wrench with a socket but that sounds like an excellent suggestion. Thanks again!

[eastbay]

Since you will be sending the heads out for rework (guessing) I wouldn't sweat it if you break a few, just have your machine shop replace them.


May as well have them replace them all anyway to get to the length you want, based on what exhaust flange thickness you want to run going forward.

[BCLi]

Originally Posted by eastbay

Since you will be sending the heads out for rework (guessing) I wouldn't sweat it if you break a few, just have your machine shop replace them.


May as well have them replace them all anyway to get to the length you want, based on what exhaust flange thickness you want to run going forward.

Thanks. Want to thank everyone - was able to get the nuts off with PB Blaster persuasion and a box wrench without breaking a stud. Removed the headers, and now figuring out if I want to add heat back to the car since I'm not in SoCal anymore...