friggin exhaust manifold studs! - UPDATE + Q's

[Ameer Antar]

Well, I figured I had to take a break from this mess and relaxed over the break in NYC. I think it did the trick. Going back to it today, I took a closer look and lucky for me, it looks like the stud actually isn't spinning... it's only the nut. I've never seen that happen before and when I took the stud out it was all bent, even though the nut never got difficult to turn. Anyway, I had a couple new nuts and studs lying around, but the studs were the original style which don't have the taper and are a bit shorter. I tried torquing this down, but it snapped way before getting to 26 ft-lbs.. Luckily taking it out wasn't bad at all. But now I have to wait till the dealer can get the new-style studs, b/c they don't even stock these things.

So I have 2 questions now... It still seems almost impossible to tighten the nuts on the manifold, esp. the lower ones on #3 and #4 cylinders. How can you do it? Will going from underneath the car help? I can barely get an open-end wrench on it, so I'm almost tempted to pull the head again and then tighten the manifold on the bench. I'd like to hear any BTDT's on this.

Do I need all new manifold lock-nuts, or is it OK to re-use 'em, since they're all-metal? Thanks again for the advice and concern! And thanks for the info on the Bigserts... nice to know there are more options, although I hope I never have to use 'em.

-Ameer

----Original Message----
From: "Jim Dupree" <jdupree914 at sbcglobal.net>
Date: 7/3/04 6:06:25 PM
Subject: Re: friggin exhaust manifold studs!

I would look close at the threads in the cylinder head. I have seen the
threads pulled loose in the hole and it looks like an insert. It is was just
a small aluminum coil the was the threads in the hole to begin with. If
indeed your head has had heli-coils installed and they are pulling out or
stripped then there is a option still. They are called 'Big Serts'. They are
by the same company the makes Time-serts (better than heli-coils IMHO). It
is a thicker insert so you have to drill a larger hole than was required for
the heli-coil but you still get to use the original 8mm studs. You have to
get a kit, it comes with a drill, tap, insert and installation tool.
http://www.timesert.com/bigsert.html

I have never used one on an exhaust stud but I have used them in other
situations.
Good Luck
Jim
1993 S4
1984 4kq
1985 4kq
1985 5kt