I got in a rush working on the XJ the other day and overtightened (snapped) the rear exhaust manifold stud. Because of its location I cannot put enough force on it for the drill bits to bite, let alone get a regular drill or dremel in there at the correct angle.. I've extracted broken exhaust studs before, but they were easy access on the front of the engine. Aside from pulling the engine back out, or purchasing a right angle drill, does anyone have any suggestions?
XJ 4.0 broken exhaust manifold stud.
- Thread starter SStone
- Start date
- Joined
- Mar 20, 2005
- Location
- Hendersonville, NC
I've done hundreds of these (literally) over the years. Don't use an easy out, they'll break. No need to drill through and re-tap. But instead, use quality screw extractors from Snap On, Mac, etc. You'll drill a pilot hole, tap an insert into the hole, slide a collar over the insert that a wrench fits around. Then turn out. Be very careful not to break off an extractor.
Or, if you have access to a welder, place a 1/2" nut over the broken stud, fill the inside of the nut full of weld (you want to weld the broken stud to the inside of the nut) and turn it out with a wrench on the 1/2" nut.
Good luck
Or, if you have access to a welder, place a 1/2" nut over the broken stud, fill the inside of the nut full of weld (you want to weld the broken stud to the inside of the nut) and turn it out with a wrench on the 1/2" nut.
Good luck
I have a few Kobalt #4 screw extractors and have a socket to pop them into so that I can extract things manually with a wrench or t-handle, virtually eliminating the risk of breaking the extractor imo. Used one to successfully extract an exhaust mani stud out of my old 240sx KA24.
It looks like I'm going to have to pull the cylinder head but I was trying to avoid it.
Thanks bud.
It looks like I'm going to have to pull the cylinder head but I was trying to avoid it.
Thanks bud.