Exhaust Manifold Stud Removal
 

Ok, I found a nice pair of ram's horn manifolds with a y-pipe and a heat riser. The y-pipe nuts came right off but the studs are rusted with threads missing.

I have been soaking the studs with nut buster every few nights, trying to turn the studs either forward or back to start some movement. I have heated studs & manifold ears but the studs are still stuck.

Do I just grind off the studs & drill & tap the holes? Does anyone have any sure fire, never fail tricks to get these out?

Re: Exhaust Manifold Stud Removal
 

Iv never had a bolt that a torch wouldn't fix. Sometimes you have to heat it several times but it will get even the rustiest bolt out. Maybe heat it up hotter? Hate doing it on things that need a straight edge but I heated up a I6 manifold stud red hot one time and it didn't cause a problem. It is super hard drilling out a bolt and getting it centered even with a drill press it is difficult.

Re: Exhaust Manifold Stud Removal
 

Cut them off and drill and re-tap. They will break anyway and you will still have to drill and tap. I replaced mine the same way.

Re: Exhaust Manifold Stud Removal
 

Heat it with a torch. I did that with mine, all 6 studs came out with no problems.

Re: Exhaust Manifold Stud Removal
 

I agree with the heat, heat it until cherry red, wait a little bit and they will come out. Slowly

Re: Exhaust Manifold Stud Removal
 

Once you get them out, or drill and tap, you might have to Heli-Coil the manifold.

Re: Exhaust Manifold Stud Removal
 

The trick is to let it cool down to touchable before putting any torque on the bolt. I have sprayed penetrating oil on the bolt as it cooled can't say it helped but didn't hurt.

Re: Exhaust Manifold Stud Removal
 

Candlewax

Heat the stud and manifold area, drip candlewax ( from an ordinary candle ) right onto the threaded area of the stud-manifold ( just like the rust buster you were using ). this will melt down into the threads and provide a nice lubricant when you go to remove the studs..... wont burn up like most wd40 type stuff does

Re: Exhaust Manifold Stud Removal
 

x2 on the candle wax trick, works great