Exhaust manifold Bolt spinning

[CiscOsys311]

I`m starting a clutch job and i need to take the Y Pipe down. I have an 89 with 63K miles but the bolts are really really bad rusted. I use PB blaster about 4 times before I actually tried to tackle these bolts. I used a torch for about 5 minutes on the bolt before I turned it. Just as I thought, when I went at it after it got good and hot, the stud just turned in place. I am figuring that many ppl have had the same problem..... hopefully. Where do I go from here. Vice grips on the open part of the threads? I really dont know, i`m about to punt! The threads all the way down are so shot that I dont see it ever coming all the way off..... I also used a dremel with wire wheel for a little bit but it looked like it was doing more harm then good... i`m stuck. I`m about to just cut it off

ML

 

[Ishodu]

Some studs have a hex section near the manifold that you can use a socket on others don't. But it sounds like you need to replace them now for sure. You may want some real heat to remove them from the manifold, it would be nice to get the manifold red hot when removing them. If you figure you can get them out you can just cut them off, if not maybe it would be a good idea to take it somewhere and let them replace the studs while you can still drive the car.

 

[masho95]

Ditto that... if the nuts aren't coming off the studs, then save yourself a MAJOR headache and try to get the whole stud out of the exhaust manifold. Heat up the exhaust manifold and try to turn the studs out while it's hot. I just replaced my studs and had to run a tap through the exhaust manifolds and a die on the new studs.

 

[CiscOsys311]

I cant see the head of the bolt that connects to the Y Pipe. I dunno, its morning time now, I am going out there and figure someway to get this Y Pipe off.

ML

 

[CiscOsys311]

Well, just broke the easiest one to get to. Heated it up for about 10 minutes almost till it was glowing. WOW I can still see the flame in my eyes. ANyhow, I guess I will be placing the an order for these studs and bolts.

How do I get the old studs out from manifold connection to the Y Pipe? There doesnt seem to be a head on them.

 

[Ishodu]

Heat up the manifold with a welding tip on a oxygen and acetylene torch and then twist them out with vice grip.

 

[rangerj]

After you get them out chase the threads with a tap. Apply anti-sieze compound to the new studs threads when you put them in. Use brass nuts, at least two, and brass washers when you install the pipes. Cover as much of the bottom of the threads with brass nuts as possible and you will not have the same problem the next time. Also use anti-sieze compound on the threads of the nuts.

As for getting the old ones out, as stated above heat is the only solution. Tap on the studs with a hammer to shock the rusted threads before you apply heat.

 

[DVJ38]

I hate exhaust manifold bolts!!!!!!

I just replaced my rod bearings. I heated the exhaust manifold around the studs up with Oxygen and Mapp Gas torch till they were glowing red, and before that I used PB blaster 3 times. I broke all 4 exhaust manifold bolts. There were no threads sticking out of the nut it was so rusty. So then I tried getting the rest of the stud out with vice grips after the Y-pipe was off. That didn't work, so then I dremeled them flat and drilled the studs out and tapped the holes and bought new bolts nuts and washers. The back manifold went fine, but in the front the drill bit broke (the smaller one used for a pilot hole) and I couldn't get it out. So the other hole went fine and then the tap broke in the hole. Figures. The bolt and tap and nut fit perfectly in Home Depot. Once I tapped it, the bolts didn't fit at all. I've tapped before and it was perfect. This time it all went to ****. So then I tried to get it welded on, but I guess the metals had 2 different rates of heat expansion so it wouldn't work. This welder is very technical I just wanted it done. So he recomended these Exhaust ****** Clamps. (Clamp-a-******) I never heard of it. It looks like it'll work. It better, I need to get my car on the road here.

I would pay someone to do it. It will save you a HUGE headache. Just take it in to a shop have them replace the bolts. Then you can drive it back and just take them out and do the work you have to do yourself. No other bolts should be rusted. Everything came off no problem except one of the starter bolts. It was on there so tight, the one that is on the top of the starter. My friend benches 300 lbs and was BARELY able to get it off after trying a long time.

 

[CiscOsys311]

DVJ, thanks for the comments. I have the same torch that you bought, Oxy and MAPP gas specialty torch. I am going to use more heat on the back bolts. I broke one of the front ones but luckily I can grab on the threads. I am just going to heat it up and heat it up, time to go asssume the position. This time I am wearing sun glasses and goggles.

 

[platoribs]

DVJ, thanks for the comments. I have the same torch that you bought, Oxy and MAPP gas specialty torch. I am going to use more heat on the back bolts. I broke one of the front ones but luckily I can grab on the threads. I am just going to heat it up and heat it up, time to go asssume the position. This time I am wearing sun glasses and goggles.

Where did you get the Mapp/oxy torch setup please. I'm tackling this job too, going to load Josh's Stainless Steel stud and nut set today so hopefully if I can get them swapped out I'll never have to fight the y-pipe again!

I've been thinking about removing the manifolds so I can take it somewhere and pay them to do it. But thought I'd at least do the math on the cost of buying the stuff to do it myself and compare that to the cost of having it done and running the risk of some goofball breaking my manifolds.

 

[masho95]

The trick to heating it up is to heat the exhaust manifold NEXT to the stud until it's glowing red. You don't want to actually heat the stud up.

 

[slickn56]

Are you guys using an impact to get the nuts off..... Ive done plenty of cars from massachusetts and have only broken studs when using a regular wrench to turn the nut.... Ive never broken a stud with heat and a good impact.

 

[CiscOsys311]

I used a copper pipe over a ratchet for leverage. I ended up breaking 3 but I knew they had to be broken. There did not even look like threads past the nuts even after I dremeled it.

Where can I get a new set of studs? I tried to email Josh but he hasn`t returned my email in over a week. Anyone know the prices on the exhaust studs and nuts. Y Pipe and Spring Nuts and bolts (broke these too) and the Ball joint Bolt and nut. Am I missing any other stuff that may need to be replaced. Nuts and boltswise?

The OXY - MAPP gas torch was from Home Depot for around 50bucks. I think I may have already ran through the oxygen, I will check it tomorrow.

 

[Ishodu]

You must have typed Josh's email incorrect or something I never heard of him not retiring a email. Check is web site most of the stuff you need he has.