Exhaust studs sheared - Toyota Nation Forum : Toyota Car and Truck Forums

PaulSwany · 12-29-2010, 02:51 PM

I've got a 96 Camry 4 cylinder automatic.

I'm replacing my oil pump and oil pan gasket. Had to pull the exhaust pipe to get the pan out. 2 of the 3 studs sheared off... Got the motor buttoned back up... But now I'm trying to figure the best way to heal these studs. There's a little bit of stud sticking out of the exhaust manifold that I might be able to grab with some vice grips to get it out... but if it wouldn't turn with a 1/2" breaker bar, what makes me think I'll get it out with some vice grips?

I'm thinking liberal amounts of PB Blaster and maybe some heat... I was hoping to avoid pulling the exhaust manifold. and I was really hoping to avoid drilling the studs out....

Any idea's?

***Mister_Perkins*** · 12-29-2010, 03:21 PM

I would heat them up with a torch and spray some blaster on them once they cool down. Try to put the grips on there then. Keep in mind that a Propane torch will not do the job. You need to have Oxygen and acetylene torches. When heating dont apply direct heat to the bolt, because you will weaken the stud. Apply the heat on the outside flange of the exhaust manifold, heating up around the bolt. This will expand the outside metal and keep the stud at a cooler temp (Outside expands, stud retains shape for most part)

Wost case scenario is that you will have to drill the bolts out and tap the exhaust manifold bolts.

If you end up just wanting to swap the exhaust manifold out, I have a spare manifold from a 95 that is the same (O2 sensor missing).

PaulSwany · 12-29-2010, 08:05 PM

You think I should pull the exhaust manifold to pull the studs?

Chris Crash · 12-29-2010, 08:47 PM

It would be a lot easier. It's only a couple more bolts.

***Eye8Pussies*** · 12-30-2010, 09:39 AM

^

you can try drilling the studs out with the manifold on, but since you have a 4banger, there is no rear exhaust manifold to deal with, and is pretty easy to get out. at that point, it'll be pretty easy to remove the studs with the manifold on a work bench

***Mister_Perkins*** · 12-30-2010, 09:40 AM

Yup . the manifold gasket is only $12 - $15.00 too so thats not a big deal changer. Make sure to get the circle manifold gasket for between the downpipe and the exhaust manifold too

PaulSwany · 12-30-2010, 09:57 AM

It looked like there was a lot more than a few bolts to get it off... Two supports from below, an O2 sensor and a bunch of heat shields...

***Mister_Perkins*** · 12-30-2010, 10:12 AM

You can leave the O2 sensor connected, just disconnect the plug.

Remove the heat shield (12mm), remove the Support bracket (14mm) remove the alternator adjust / support bar (12mm). Slide the alternator bracket up out of the way. Then just a bunch of exhaust manifold bolts.

PaulSwany · 12-30-2010, 10:17 AM

Cool... as long as none of the other exhaust bolts fight me like the ones for the pipe, I'll be good to go!

Chris Crash · 12-30-2010, 12:08 PM

Soak the bolts on the head with PB blaster or liquid wrench. Those ones like to be stubborn.

Stillrunning · 12-30-2010, 01:48 PM

The possible problem with taking the manifold off is you might find yourself in a bigger pickle if you also break some manifold studs in the head - be very very careful. If there's hardly enough broken stud to grip with visegrips then you'll end up drilling them out anyway, manifold in or out. If the two broken ones are at the front and accessible for a drill I'd drill them out. You can use a nut and bolt if you mess the threads up for studs. Even using an Oxy/Acet torch (which it doesn't sound like you have) may not loosen them enough with limited grip.

PaulSwany · 12-30-2010, 03:36 PM

I'm thinking I'm gonna weld a nut on the end of the stud and soak it with lots of PB Blaster. It would be a lot easier with the exhaust manifold off... Just not sure I wanna chance it.

Chris Crash · 12-30-2010, 03:48 PM

Sounds like a good plan.

Stillrunning · 12-30-2010, 04:27 PM

Quote:

Originally Posted by PaulSwany

I'm thinking I'm gonna weld a nut on the end of the stud and soak it with lots of PB Blaster.

Welding doesn't work too well with hardened (high carbon) steel as the stud probably is and maybe the nut as well, even harder with dissimilar metals. Also you'll be welding upside down with limited access - not easy either.

Good luck.

PaulSwany · 12-30-2010, 10:17 PM

I ended up removing the exhaust manifold.... It was a non event, came right off. The first stud came out pretty easy after I welded an old lug nut to it. The second one sheared off two times after I welded the nut to it... The third time, I welded a bolt to it and it came out... Put it all back together and fired it up! Everything is good to go! Thanks for your help guys!