Should I try to remove these......

[gjmascoli]

Dropped the engine for a bunch of upgrades including installing SSIs and removing the Air Injection system on my 2.7L

1) I was very lucky to get the old stock exhaust off without any drama...no broken exhaust studs, but they are really trashed - lots of rust. I know I should replace them, but I am afraid I will break at least one, if not all, of them. Is there a proper stud extractor tool (like the Snap-On) that will prevent me from breaking these as I remove them?

2) Also, the Air Injectors appear to be a problem. Two came right out after overnight soaking in PB-Blaster. Three are definitely yielding as I apply torque. One I already broke off. I'm hoping to remove the one I broke using a bolt-extractor - worst case is I drill and chase the thread in the head. The other three I might just leave in place and cap the ends. Anyone else have trouble with these?

I'm not planning on doing any head work, so I am trying to stay away from drilling and tapping.

Also, I am not blessed with an air compressor or impact wrench.

[Flat6pac]

If the engine was a thermal reactor engine the studs will be 8mm with a thinness in the center so you can rock the thermals on and off. You need to apply some heat even if its a mapp torch to try to save the studs.
Bruce

[JJ 911SC]

If all your stud still intact your are more then half way there.

You need a straight stud puller. I did all mine using it on a air gun starting at 30lbs for 10 seconds then increasing by 10 pound.

Only one broke twice (flush the second time) so I had to do a time-serf. See Post # 8 of Help... Exaust Stud Drilling

Titan Stud Puller — 3/8in. Drive, Model# 16023 | Multi-Drive Specialty Sets| Northern Tool + Equipment

[gjmascoli]

Thanks, the Titan Stud Puller is what I was thinking I would need.

Any thoughts on the Air Injection thingees? Leave 'em be?

[gjmascoli]

Just an update after a year. I ended up breaking 10 out of 12 studs and 4 out of 6 air injection pipes. Lots of drilling and tapping was done :-( with the engine on a stand.

[GH85Carrera]

Originally Posted by gjmascoli

Just an update after a year. I ended up breaking 10 out of 12 studs and 4 out of 6 air injection pipes. Lots of drilling and tapping was done :-( with the engine on a stand.

So by the 14th stud you were pretty good at it.

[john walker's workshop]

my advice would have been let sleeping dogs lie.

[Tidybuoy]

Live & Learn. I recently pulled my 2.7 and decided to replace the exhaust studs. Against the advice of this board, I soaked all the studs for a week or so an then proceeded with the removal. I broke 5 of the 12. After that, I stressed for a month and then got busy with drilling out, and installing Time Serts. Everything worked out in the end but next time I may listen better.