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Old 02-09-2004, 11:16 PM   #3
Jason Spears
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Join Date: Dec 2002
Location: Stoney Creek, ON
Posts: 89
You don't need to buy a new manifold! You can get a broken stud out with a little heat. The hardest part will be getting something that will hold onto the stud. The best thing to do is weld a nut to the stud. Heat up the manifold with a torch and then back the stud out. There are also special stud extractor tools but the welded-on nut works best.

If the stud broke off flush with the manifold you will have to drill out the stud. The studs are 3/8 inch course thread so you will need either a 5/16", size"o", or size "P" bit to drill it out. Use cutting fluid. The cast iron is harder than the stud material so it shouldn't be too hard to keep it centred. The use the appropriate tap to clean out the threads.

You can get a manifold stud kit c/w brass nuts for about $5 in the "Help" section or at any auto parts store to replace your broken ones.

Next time, heat up the nuts before you try to take them off the stud! It will save you a lot of grief.

Good luck.
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