Pulling and replacing exhaust studs

[xsacta]

First, spray down the studs with a good penetrating spray like Gunk super penetrant. Double nut and lock them together and back out each stud. Hint: Before you start rotating the stud counterclockwise, give it a very small turn, no more than an 1/8 turn,clockwise. Very Little! Re-sray with penetrant. then remove. Since you're going to replace the studs, you can clamp one in a vise and experiment with a drill type that will cut in. Try to center punch the end first. You should then use a center drill after that to get things going. Try to use a stubby drill bit. It's unlikely that a typical high speed bit is up to snuff, but give it a whack. Titanuim coated or possibly ceramic coated maybe, but maybe not. Plenty of cutting oil and slow cutting speed is a must. A solid carbide bit would probably be the first choice in a machine shop with the head properly clamped down in a milling machine or a drill press. Carbide won't last long if you don't have a very steady hand, or if there is runout in the chuck of your drill gun. Of course you'd use the proper sized bit for the easy out you'll use. The stud OD is a heavy 3/8" (.387) the minor thread diameter is probably about 5/16" (.312) A 1/4" easy out may be a bit too large because the chances of you drilling the hole dead nuts center, freehand and perpendicular hanging over a fender, is small. Choose the next size down. Good Luck


*Somehow my response has posted before your question!

I have an '84 22r and am wanting to replace the exhaust system from the head
out. I have one broken stud. I've removed broken or stripped bolts from
motorcycle blocks before, but I'm told that the exhaust studs in this engine
are much harder and being old will be difficult to remove.

First, how do I remove the broken one and second, how do I remove the
unbroken ones? Please give some detail. In essence, I know how, but I want
to remove them with the least amount of trouble and not pulling the engine
out or apart. What lubricants should I use and what bits, etc.?

Thank you

On Tue, 18 Jul 2006 20:55:50 -0700, "Brad Taylor" <BradTaylor@ev1.net>
wrote:
[color=blue]
>First, how do I remove the broken one and second, how do I remove the
>unbroken ones? Please give some detail. In essence, I know how, but I want
>to remove them with the least amount of trouble and not pulling the engine
>out or apart. What lubricants should I use and what bits, etc.?
>
>Thank you
>
>[/color]
I have removed broken exhaust manifold studs sucessfully in the past
using the "Studout or Screwout tools. They are a combo left handed
drill bit and self threading left handed collet. You just select one
that is a little smaller than the stud,center punch it, drill in and
then use a wrench on the collet which will grab the inside of the
drilled out stud. Carefully work it out in a CCW direction. But first
heat up the area with a torch and then soak with Marvel mystery oil
penetrant at least overnight. When drilling the stud, go slow, with
very little pressure, the Studout drill tip is a titanium alloy and
will go through any steel, but if you snap it off then the only way to
get out the broken part is with a diamond tipped Moto tool tip. They
are lifetime garunteed, if you break one, just send in the pieces and
they will send you a new one, no charge. The unbroken studs I would
heat up with a torch and soak with penatrant over night, then use the
double nut method or buy a stud remover. This method worked for me
more than once. Good luck and go SLLOOOWWW. JMTCW

"Joseph Myers" <joemyers@ev1.net> wrote in message
news:qg01c259r9mm2pjk6v4thuab2t5beu5mno@4ax.com...[color=blue]
> On Tue, 18 Jul 2006 20:55:50 -0700, "Brad Taylor" <BradTaylor@ev1.net>
> wrote:
>[color=green]
> >First, how do I remove the broken one and second, how do I remove the
> >unbroken ones? Please give some detail. In essence, I know how, but I[/color][/color]
want[color=blue][color=green]
> >to remove them with the least amount of trouble and not pulling the[/color][/color]
engine[color=blue][color=green]
> >out or apart. What lubricants should I use and what bits, etc.?
> >
> >Thank you
> >
> >[/color]
> I have removed broken exhaust manifold studs sucessfully in the past
> using the "Studout or Screwout tools. They are a combo left handed
> drill bit and self threading left handed collet. You just select one
> that is a little smaller than the stud,center punch it, drill in and
> then use a wrench on the collet which will grab the inside of the
> drilled out stud. Carefully work it out in a CCW direction. But first
> heat up the area with a torch and then soak with Marvel mystery oil
> penetrant at least overnight. When drilling the stud, go slow, with
> very little pressure, the Studout drill tip is a titanium alloy and
> will go through any steel, but if you snap it off then the only way to
> get out the broken part is with a diamond tipped Moto tool tip. They
> are lifetime garunteed, if you break one, just send in the pieces and
> they will send you a new one, no charge. The unbroken studs I would
> heat up with a torch and soak with penatrant over night, then use the
> double nut method or buy a stud remover. This method worked for me
> more than once. Good luck and go SLLOOOWWW. JMTCW
>[/color]

Thank you. Just how do I go about heating up the stud? I assume a propane
torch. Could I damage the head?

[xsacta]

Brad Taylor wrote:
"Thank you. Just how do I go about heating up the stud? I assume a propane
torch. Could I damage the head?"

I'd resist the temptation of heating up an aluminum head with a torch of I were you. But that's just me.