FUBARd exhaust manifold stud/nut

JedGrant

JedGrant

Well-Known Member
Joined
Mar 12, 2012
Location
Charlottesville, VA
I managed to get all but one nut out of my exhaust manifold. I’ve soaked it in PB, rounded the nut, heated it, and now have broken off the torx head trying to extract the stud. Just trying to see if anyone has any good advice for removing it. I have the ability to weld but it’s a pain in the ass to set up my welding gear here. My best bet is likely to thread a nut over the stud that I can see and weld the inside of the nut, but then I’m back to square one trying to loosen the nut in a tight space. Any ideas?

Burning the whole thing to the ground isn’t off the table either.
 

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Soak it in 50/50 atf and acetone
Heat cycle it
Let it sit 24 hours.
Then try whatever
 
I was thinking the same thing, go at it with a Dremel or die grinder. Split the nut, run it off the stud, then try to get a good bite on the stud once the exhaust manifold is off.
 
That's the issue with flange nuts on exhaust stuff. The flange gets seated and stuck, but as soon as you break it loose...it'll likely thread off by hand. That flange has a lot of grip/surface area!

I'd cut it/grind it.
 
Agreed about the flange, there’s a lot of surface area (and rust) that holds it to the manifold. I had a tough time getting the gun in there but I managed to weld it in two spots and it came on out with the heat. The problem with the dremel is the picture doesn’t do justice to how tight it is. Thank you all for your help! Now for the other side…
 

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NickMaul said:
Could one of these work? Never really had a use for one of these before but this sort of looks applicable.

Click to expand...
that thing looks like something you'd never want a scorned woman to get ahold of. Especially with that name.

For future reference another last-ditch trick is a left-handed drill bit. Not an extractor, literally bits that go counterclockwise.
One of two things happen - either it will eventually bite enough to spin the screw out (my experience 95% of the time) or you end up drilling it out and then you can get the remainder clean with a tap.

Requires reasonable access though.
 
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