Thread: Exhaust Bolt Replacement

Hey fellas. I snapped one of the studs that holds the primary and secondary together. What is involved in putting a new stud in there? I've never really had to do that type of job. Just wanted to get some opinions from people that have. I searched but I couldn't find anything regarding that stud, just the exhaust manifold studs.


Also I suggest using an impact wrench for this job. I used an impact wrench for the center stud and the nut came off no problems. I'm about to get an impact extension so I can use my impact wrench on the last nut. I wish I would have had the extension for the first nut.

Are you using a stock manifold or a aftermarket one?

Oh sorry. I didn't specify that. It's a stock exhaust manifold. Stock primary, to stock secondary.

The stock manifold uses studs instead of bolts. It can be extracted and replaced, but you might consider just finding another manifold. I've thrown 3 or 4 of those away. I'm sure someone in your area has one and they wouldn't want much money for it (somebody would probably give you one). That would save the hassle of removing the broken stud.

I actually have a spare motor I can pull a manifold from. My concern is that I don't want to mess with any rusty fasteners if I don't have to. THe exhaust manifold to head studs are what concern me the most. Since I currently don't have any leaks at the top of the exhaust manifold, I'd rather not mess with something that is not broken.

Thank you for the suggestion though. I might have to go with that option if I it comes out to be the best choice for me.

i would just drill the stud out and use a nut and bolt with lock and flat washers. No need to press in a new stud.

Exactly what I did with one of mine. No issues at all, just be careful since the manifold is going to be softer than the stud, you don't want to drift around when drilling. Just remember to use some nice metal bits and drill a pilot hole first for alignment.

Done that on a couple of CATs when the nuts were rounded off. Just be warned, if you use old drill bits it will take forever. I would highly recommend getting some new bits or you will be under the car for a long time as those studs are tough metal.

Well I drilled it out with some metal eating bits. I then put in a thread insert it's M10X1.5 for the people that check this thread later on.

Drilling that old stud was a pain in the ass though. Took forever to get the hole started. I almost quit to swap exhaust manifolds but I decided to see it through to the end.

Anybody have an idea of what torque that stud is supposed to get? I could not find that info in the FSM.

I hope it works. The only problem I see occurring now is that the stud might not be aligned right. I eyeballed it but that is not precise at all.