HELP!!!! Can anyone help drill out exhaust manifold stud.

[99gtt]

Just picked up a new stud and nut for my caldina as the old one disapeared and i have a leak. Problem is the old one is snapped off inside and i have been trying to very carefully drill it out myself, but haveing no luck. Can anyone help me please, i am in papakura.

[Mr Revhead]

are you still running the stock manifold?

[Ae92typeX]

what exactly do you mean by you have been trying to carefully drill out but are having no luck?
they so often break, but have you tried an easyout yet? (after soaking in crc over night.

[bad20v]

Don't drill it out. Make a cross cut across the broken face of the stud, wide enough to get a large 'flathead' screw driver into the slot you have just made in the stud. Then just turn the screwdriver anti-clockwise till it comes out. If the stud won't turn coz you can't grip the screwdriver hard enough, get a large crescent wrench or vice-grips and put those around it to get you better leverage.

DISCLAIMER: I take no responsiblilty for any damage to your car if this doesn't work, but I have done it this way to several cars with no problems and it works every time.

[99gtt]

yes i have stock manifold and the stud is snapped off flush with the block . I know this is really common , but i thought they wriggled loose not snap right off.

[Ae92typeX]

Don't drill it out. Make a cross cut...

thats also assuming it has broken with some face you can do it to, and not broken in the head where you cant slot.
but if it does protrude yea, either that or file some good flats on the sides to get an adjustable on.
(or weld a nut on top and take out as per.

edit...bah, bet me to it...

[99gtt]

[quote="bad20v"]Don't drill it out. Make a cross cut across the broken face of the stud, wide enough to get a large 'flathead' screw driver into the slot you have just made in the stud. Then just turn the screwdriver anti-clockwise till it comes out. If the stud won't turn coz you can't grip the screwdriver hard enough, get a large crescent wrench or vice-grips and put those around it to get you better levera


Sounds like a good idea but have nothing small enough to make that sought of groove.

[MrOizo]

can you get reverse threaded drills?

with studs you'll need a high speed steel bit but use it at a low speed - making sure you oil it up and keep it oiled...


but yeah - i'm sure you an get a reverse threadded drill bit and it helps work it loose when you are drilling it

[Ae92typeX]

as long as one can drill as big as possible a hole centered in the stud, it mainly works with easy outs in my experience.
on occasion it hasnt worked for me though and Ive ended up drilling out and helicoiling, or upping to the next size thread.

[fivebob]

You'll probably have to make up a guide that you can bolt to the head and then drill through it to make sure that you drill out the centre of the bolt. Failing that you might have to remove the head and get the stud EDM'd out.

[Mr Revhead]

ok if you have the stock manifold that came with your car then the manifold will be warped, thats how it snapped the stud.

unfortunatly the only fix is to replace it with a new turbo and manifold from toyota. the new item has an extra lug on it by the no1 port.

[Ae92typeX]

ive had no experience with these manifolds, but would it not be possible to get it surfaced assuming it is warped? (not that it would help in the long run if its a common issue0

[Mr Revhead]

no, itll just keep warping.
its a design flaw.

[Ae92typeX]

bummer...handy to know though

[evil_si]

if its close to the surface or flush, i prefer to weld a nut on to the broken stud,

the direct heat and the fact you have welded a nut on, makes it easy to undo.

[gazza_jay]

bummer man... my experience with broken studs that break off flush with the head I center punched the center of the stud. then go a very small drill bit and drilled where I punched it.. only drill like 10mm tho with the small 1.. Im unsure of the length of ur stud.. then get a slightly larger drill bit and drill again but smaller than the threaded hole. if u got a tap use that 2 start a thread if ya lucky u might remove most of the old stud if not drill 2 the size required to make a new thread... easy outs dont like me lol or maybe I dont know how ta use em right but the method I just said has got me by many times.. u get use 2 it afta a while if ur car keep breaking them

[gazza_jay]

welding a nut or bolt works if ya have the equipment, good luck I just had 2 do 1 2day on a 20valve head which are a peice of cake 2 do

[Wildcard]

All this talk of warped manifolds makes me want to do some preventative maintenance on mine, can anyone confirm for me if the Gen3 head has the thread already tapped for the extra exhaust manifold stud?

[99gtt]

yeah there is a thread tapped allready dumb that they never used it.

[Mr Revhead]

the mr2s dont appear to have the same issue.
but yes there is a hole there already. no idea why it isnt used, i think some jap guy missed a line on a drawing or something