Another head stud question!
 

I recently posted a head stud question and received an enormous amount of very helpful input. Yet I have another for you all and this may sound like a no brainer but I am fairly new to this site and to the Porsche world so please bear with me......I have at least one broken stud flush with the case will my machinist have to disassemble the case in order to drill this stud out?
I am asking because I was not planning on this costly repair and I want to get my car back on the road before summer!

Thanks,

If one is broken flush and your replacing them all then i would try and get them [the rest]out.It can be done im sure,but if more break off then i would just dissasemble for fear of particles getting in there.

Most likely just the top end....do a Google search on EDM stud removal. They use an electric charge to disolve the stud.....

When replacing go with steel upper and lower.

Replace all the lower ones with steel ones (same part used on top rows). Electrical discharge machine (EDM) may be able to get the broken stud out without splitting the case. How many miles on the engine? If it is low, don't split the case and keep it simple.

Mike Z., you must have hit the send button 1 millisecond before me. :)

The engine has only 94K on it and no signs of needing a rebuild. I will definately replace all of the studs.
That brings up another question......if the Dilavar studs did not hold up and broke apparently all of the freakin time why are they still offered?????????
I will use the steel upper and lower like all of you have been telling me, besides that is several hundred dollars cheaper!

Because people are freaking stupid....

Ok, just wanted to hear it from someone else.

Which stud is broken. I drove around with a broken middle cylinder stud (I think it was lower and broke because the coating got nicked years ago) for about 50,000 miles. When the shop I use did a total rebuild they found no damage as a result of the broken stud.

If you hear a farting sound or like a playing card in the bicycle spokes....you are losing compression. Irritating as hell.....when I redid mine, I added the 964 cams and the engine had a new life.....it was a VERY noticeable improvement.

There is no telling how many miles were put on the engine with the broken studs, I have only removed the driver side valve cover and have found 3 broken, have not even bothered looking at the pass. side

Mikez,
Where do you get the 964 cams? And what all else needs to be changed for this addition?

Pelican carries them...or you can have the old ones reground....

I like to do as much work as possible myself, and have drilled out many broken fasteners in my day. But I would not do this with these studs. If one is truly broken flush, I would find and EDM guy and have it done. I would first remove all the exhaust studs, to make sure. And if I needed to split the case, fine. I might do this anyway. That way, there would be no dirt or metal shavings hiding in the case. Again, bear in mind that once the cylinders are off the engine, you can count the remaining parts on one hand, including the two case halves. The only things in there are a crank, an oil pump and a layshaft. Oh, and sixteen bearing halves with at least some wear.