How To/DIY::Remove broken manifold studs

[Jamison182]

Hello everyone. I recently removed my turbo kit, and while removing the exhaust manifold I snapped a stud clean off. Sooo, I thought i'd do a short write up on how to remove damaged, stripped, or broken intake/exhaust manifold studs.

Tools needed:

- Safety glasses
- Tap/Reamer wrench
- Screw extractors(I used #3)
- Drill
- 5/32 drill bit
- PB blaster penatrating oil
- Brake cleaner
- Beer

First off, I started by spraying the broken stud with PB Blaster penatrating oil. This helps free up the back of the stud. I let it sit for an hour or 2.

Next, I took a 5/32 drill bit and started to drill the center of the stud. Its very important to deep into the stud. I drilled in about a 1/2 inch deep.



Picked these up at Sears for about 25 bux, worth every penny!



After your done drilling, spray more PB blaster around the threads, It can only help. Now your ready to start extracting the stud. Very carefully, take the #3 extractor bit, and begin to thread it into the broken stud. Rotate the tap wrench counter clockwise VERY VERY slowly until deep seated into the stud.



Once the bit is firm into the stud, twist that bitch outta there. You may notice the extractor bit start to flex so be careful not to snap it.(I bought spares incase that happened). If done right, the stud should start backing out.



WOOT!! You got it out, now you can spray brake parts cleaner in the threads and side of the block to wash away any metal shavings. I encourage anyone doing this to wear proper eye protection at all times. Now that everything is cleaned off, inspect the inner threads for damage. Re-tap if nescessary, however mine cam out perfect.

Last step, clean up your mess and enjoy your beer!!



This job was very easy!! I read many threads with ppl that just ignored broken exhaust studs which I thought was sorta lame. Don't take the easy way out. Hope this write helps anyone!