question about broken heat exchanger stud

[bell]

i was going to pull my heat exhangers to be able to change a mal-sealed oil return tube (the one between 2&3) which leaks tiny bits under very heavy right hand cornering.
problem is......all my studs are going to need to be cut off......been trying with oxy/ace heat and 4 weeks worth of of pb blasting, plus the allens are stripped (previous owner?).
right now there is one broken stud, cylinder #2 hex, broke flush with the exchanger.........

here's the dilema......being the stud which broke is in the "middle" cylinder will the others keep this secure from an exhaust leak? i would think so being nothing has broken free......if i end up having to cut all the studs it's definately not going to get done in time for hershey and my vacation.....hence the dilema
this will be addressed after heshey

thanks
in advance

[Rot 911]

First, unless you have an air pump (and I don't think any 3.2's do, you can change the oil return tubes without pulling the exchangers. Really you can. Do a search where I did it. You may or may not have an exhaust leak. The only way to find out for sure is to wait until the engine is cold. Put the rear up on some jack stands and then start the car. Quickly get under the car before the exhaust gets hot and feel if any air is escaping from #2 exhaust flange. If not, wait until after Hershey to fool with the exhaust.

[vash]

i just changed the drivers side front tube with everything in place. it was hell. i destroyed one replacement tube in the process. tricks i learned. dont install the big rubber seals until you have the assembly pushed above the exchangers. i needed everylittle bit of space. then put on the seals, lube the crap outta it. and use a big screw driver to pry it into place. i used the exchangers for leverage. oh, yea i have an air pump.

[Jadams1]

Not go to Hershey? I'll drive up to Ohio and pick you up myself! Sorry to hear about your dilema. If you have to drill out the stud, there is a jig that someone made (JW?) to accurately drill out the offending culprit. I hope I never need it.

[rick2]

Where do you get this jig, could come in handy one day?

[Jadams1]

rick2,

I saved the picture from a post that involved JW and some other pelicans. I think they were doing a SSI install workshop/clinic somewhere? Hopefully someone will chime in on this.

[Doug Zielke]

Yep, that's JW's exhaust stud drilling jig.
I've seen this useful tool in action.
I remember him telling me he was thinking on having some made. John?

[RoninLB]

Originally posted by bell


here's the dilema......being the stud which broke is in the "middle" cylinder will the others keep this secure from an exhaust leak?

it should be OK

[bell]

thanks........i'm going to run her to get the mobil1 warm this week, i'll listen/feel for leaks......but i think it'll stay sealed.

[RoninLB]

maybe use a length of 3/4 tube to reach the flange and your ear.

I have an electric gizmo exhaust leak detector for entertainment.