Sheared Mannifold to Downpipe Studs! :(

Having discovered a blow on the nearside joint from the downpipe to manifold, I got a new gasket for it and squirted a liberal amount of liquid spanner on the bolts last night. This morning I squirted a bit more and let it soak in while I had a coffee...then the first sheared clean off and so I tried the other, and now both are sheared!

Am I going to have to replace the manifold as it's not in the easiest place to get to to drill them out or does anyone have a solution for such a problem?

Thanks

Remove the minifold take to bench and you can drill it just fine.

As Gaz says, remove the whole thing, drill 'em out and use copper grease on the nuts and bolts you replace the studs with ..

They are pressed studs, if you have oxy/acet then you can just heat the surrounding flange and whack it out with a hammer (they press in from the top), if you get it nice and hot they will come out quite easy...

Failing that remove it and drill it....

Have no Oxy!

I was thinking about removing the manifold, but worried about sheering the head bolts to manifold...that'd be way beyond my diy remit!

tdi ? ,head studs should come out fiine,never found them difficult ,bolts on manifold to down pipe are threaded

rusty7 said:

Have no Oxy!

I was thinking about removing the manifold, but worried about sheering the head bolts to manifold...that'd be way beyond my diy remit!

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They will come out fine, if the nuts dont come off the studs the studs will come out the head...

it's a V8.

Thanks guys. Gotta go do a job and then I'll have a go when I get back!

Can I re-use the gasket manifold to head? Kinda need the truck for eventing on Saturday and not got the time to order a new one...

in wich case be careful

rusty7 said:

it's a V8.

Thanks guys. Gotta go do a job and then I'll have a go when I get back!

Can I re-use the gasket manifold to head? Kinda need the truck for eventing on Saturday and not got the time to order a new one...

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I wouldn't gaskets can be funny things that look ok but are really fooked.

But as James said be carful

If you do re-use the gasket, use the slightest smear of gasket goo too, and I do mean just a smear, take time to not get any blobs on the mating surfaces. If the gasket isn't blown or torn and nackered it should be OK (ish) ..

ive got a manifold u can have gez if u pay postage, tdi not v8 ??

Thanks for the offer Amigo but it's a v8 and I've managed to beat a few clamps with the birmingham screwdriver into a weird shape to secure the 2 sections together to get me through tomorrow.

And ordered a pair of stainless tubular manifolds and new gaskets all round. Just need to find a suitable replacement for the rest of the system now.

Thanks for all the respose though guys! Appreciate it!

Next dumb question...

...What's the actual difference between manifold gaskets for the v8 EFI and non EFI?

Surely there can't be that much difference, if any?

invest in a heli-coil kit and then have the confidence that if you do thread the manifold studs, you're equipped to sort it

Want to change the downpipe on my disco 2 but the bolts on the manifold are fused tight had a go at trying to remove them but they feel like they are about to shear, if they do does it mean a new manifold

Junder said:

Want to change the downpipe on my disco 2 but the bolts on the manifold are fused tight had a go at trying to remove them but they feel like they are about to shear, if they do does it mean a new manifold

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soak them first double tt spray works for me, generally most manifolds sheared studs can be centre punched and colbalt drilled out.

If you have access to an welding torch heating first helps as well

Nope! new manifold gasket and also Y pipe gasket every time.

.. and try tightening them a smidgeon first to break the lock ..

If you replace original studs with stainless ones they won't seize up nearly as bad next time it all has to come off