Disco 2 Sheared exhaust manifold stud..........Bugger!

Rushjob · Dec 22, 2018

Well, as per the title, The Td5 has kindly started to shriek under load and after taking a look around the engine bay, I've found a sheared stud on the exhaust manifold , lower row, second one back from the front. It appears to be either flush with, or below the surface of the head ( not removed the manifold yet ) so have any of you any top hints or suggestions, I'm currently in the drill out and re tap camp.
I'm now off for a sulk............

freelance · Dec 22, 2018

Drill and use an easy out, chances are stud won’t be seized if it broke in use

Irishrover · Dec 22, 2018

freelance said:
Drill and use an easy out, chances are stud won’t be seized if it broke in use

I'll go with that. Use the clearance hole in the manifold as a guide to dimple the stud. If the stud is an M8 use a 8.5mm drill first to just put a dimple in the end of the stud before using the easy out drill. That way, the hole should be pretty central in the stud and not break through the sides. If the stud is a M10 then use a 10.5mm drill as a starter etc.

Bantam1 · Dec 22, 2018

Irishrover said:
I'll go with that. Use the clearance hole in the manifold as a guide to dimple the stud. If the stud is an M8 use a 8.5mm drill first to just put a dimple in the end of the stud before using the easy out drill. That way, the hole should be pretty central in the stud and not break through the sides. If the stud is a M10 then use a 10.5mm drill as a starter etc.

I've never had any joy with an easy out, in fact the name is completely wrong they should be called no chance of getting out.
I'd keep in mind the drill out so dont snap the bloody easy out in there.

Rushjob · Dec 22, 2018

That's why I'm thinking drill, I've had bad experiences with easy outs before.......

jamesmartin · Dec 22, 2018

the spline type do work and are the best i find , its worth hitting the broken stud a few times with a pin punch of the same size as stud before drilling the hole

Bantam1 · Dec 23, 2018

jamesmartin said:
the spline type do work and are the best i find , its worth hitting the broken stud a few times with a pin punch of the same size as stud before drilling the hole

Possibly easing the thread I suppose. Always a good idea to hit things with a hammer but maybe a little heat to the surrounding area too!

winchman · Dec 23, 2018

jamesmartin said:
the spline type do work and are the best i find , its worth hitting the broken stud a few times with a pin punch of the same size as stud before drilling the hole

I have two sets of these one Facom and the other is Ridgid tool co. Very rare they fail, traditional Easy outs are tapered and don't work as well.
The key is drilling it central, I have sometimes made a bolt on guide so I know the drill bit is in the middle of the stud as the supplied guides are good but sometimes you just don't have the size.
I would soak it in Plusgas for a few days and drill it with a good quality left handed drill as often that's enough to loosen it and it may unscrew its self whilst drilling it.
If you call Presto tools tell them what you are trying to drill and you can buy for about £8-10 a much tougher drill bit exactly suited to the application so making it easier.
https://www.presto-tools.co.uk
You might have a local garage who has done loads of these and sometimes its worth getting it done by some one experienced with all the correct gear rather than struggle, good extractor sets are well over £100
https://primetools.co.uk/shop/facom-885-stud-extractor-set/
Amazon product

I dont know if I would trust this?
https://www.ebay.co.uk/itm/US-Pro-2...=item3d5fdd99e0:g:rJ8AAOSwupRazk77:rk:26:pf:0

Rushjob · Dec 23, 2018

Cheers guys, some good info there. Think it'll be waiting till after the festivities now.

winchman · Dec 23, 2018

Rushjob said:
Cheers guys, some good info there. Think it'll be waiting till after the festivities now.

No problem if we all help each other it's easy.
Just take your time plan it and it should be fine, have a spare stud / bolt with a tap etc just incase it all goes wrong

Pawl · Dec 23, 2018

When it happened on ours, I used one of the spiral eazy outs & it broke inside the stud.
I thought it was going to be a head off job to get it out , but fortunately I found some 6mm dia dremel grinding attachments & managed to grind it out (very carefully) - even though it took a couple of hours.

Disco 2 Sheared exhaust manifold stud..........Bugger!

Rushjob

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