Re: [DML] Broken Exhaust Manifold Stud
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Re: [DML] Broken Exhaust Manifold Stud

Major bummer.  I would try the easy-out way.  I had a similar  problem, 
except mine came off even with the manifold, so vice grips pulled it  out.
In a message dated 5/25/2007 6:24:48 P.M. Central Daylight Time,  
gekko@xxxxxxxx writes:

I have  recently developed an exhaust leak and after investigation, I 
have found  that I have a broken exhaust manifold stud.  It is broken 
off almost  even with the surface of the head, so nothing to grab 
hold of with the  vice grips, etc.  Since I haven't been under there 
tweaking on the  nuts, I have to assume it's been that way for some 
time but the exhaust  manifold gasket finally gave up the ghost and 
is allowing exhaust gasses  to leak by.

Fortunately for me, it is the rear-most stud on the left  side which 
is (the only one which is) accessible without removing  anything, 
even the catalytic converter.

The way I see it, I have 3  options for repair.

1.  Drill out and replace with an oversized  helicoil. (could be a 
problem with space in the aluminum head - water  jackets, etc.)

2.  Drill out the entire stud and re-tap the hole  (probably a bit 
larger than stock)to replace the stud or  bolt.

3.  Drill the stud with a small bit (3/16" or so), drive an  "E-Z 
out" into it and unscrew the stud, replace with new one.

My  question is, which of these is the preferred method?  I'm sure 
this  is not an unusual problem.  How have 'we' found is the best way 
to  address it?

Thanks in advance for your help.

Craig  Werner

Fargo, ND  
1982 DeLorean DMC12 VIN 11596

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