broken studs

Tue Mar 18, 2008 1:50 pm

have got 2 broken studs in my cylinder head that are meant to hold the exhaust manifold on,what do you all reckon is the best way to remove these ? will i need to take the head off to be worked on ?
would have just got a replacement head but as its a proper alpina head wuld be a bit expensive to replace or to get a standard head to the same spec,cheers guys

Tue Mar 18, 2008 4:01 pm

At a guess these are the lower studs on cylinders 5 and 6!! All but impossible to deal with without removing the head. Most decent engine rebuild places will be able to extract the remains and helicoil a fresh thread for a few quid.Unless you are skilled enough and have machining facilities give the head to an expert.

Tue Mar 18, 2008 4:21 pm

Not impossible to do with the head in-situ..

Had to replace my exhaust gaskets (M20) a while back and one of the studs (lower one on No.6, IIRC) snapped...
A careful amount of drilling with a slow speed air-drill and then a helicoil did the trick...

Should say that I had some (expert) help and assistance...

But all done without removing the head...

Tue Mar 18, 2008 5:18 pm

Fushion_Julz wrote:Not impossible to do with the head in-situ..

Had to replace my exhaust gaskets (M20) a while back and one of the studs (lower one on No.6, IIRC) snapped...
A careful amount of drilling with a slow speed air-drill and then a helicoil did the trick...

Should say that I had some (expert) help and assistance...

But all done without removing the head...

Fortunate to have access to the proper tools. My comments are based on 'enthusiast DiY'.. extracting a stud with my range of tools is beyond my skill level... so I am prepared to pay a specialist for skills that I do not have.

Tue Mar 18, 2008 5:20 pm

I had this with Theo. Got them out using two nuts backed on to each other and a bit of heat from a blow torch. Dont go mega mad with the blow torch.

Tue Mar 18, 2008 6:19 pm

Hello, i managed to drill a hole in centre of the broken stud and remove with a easy out, but great care is needed. When you do get the problem sorted, make sure that the gearbox exhaust clamp is fitted and in good condition. I am sure that a broken gearbox exhaust clamp is one of the reasons why this happens. Thank you

Tue Mar 18, 2008 10:33 pm

cheers guys,think i'll take it to a pro as my mate has told me that they are likely to be very tight in there hence their snapping,and if i can manage to snap the easyout in there then it will be pretty hard/impossible to remove,bit of extra and un-needed expense but probably just as well removing the head anyway,needing belt and tensioner done and been lying a while so maybe best to have a look anyway,cheers for your help