Re: HELP with exhaust studs

[a6561TB@gnn.com (Igor Kessel)]

Hi Bob:

I have done this 3 times already, on my '85 5000s, on my friend's '87 5000s
and on my '89 200TQ. It is pretty straitforward, although time consuming.

DON'T take short cuts!

1a. Remove the grill!

1. Remove the intake manifold. First time I've managed to drill the #10 out 
without it, with the help of a mirror - never again! Just be careful undoing
the 6mm hex bolts that hold int mfld - they are very soft. Scrape inside the
hexes before inserting the allen. See that allen is seating true in the hex.

2. Remove turbo. It is a pain, especially the front top nut. Be carefull 
with oil/water lines, easy to break and expensive to replace. Don't spare 
Liquid Wrench or WD40, whichever your preference is. Soak all the bolts 
tonight, it will save you a lot of workout tomorrow.

3. Remove exh mfld. Carefully CENTER PUNCH the broken stud(s)! 

4. VERY CAREFULLY drill the hole(s) w/drill bit of the size appropriate for 
the particular easy-out. Try to find an angle drill. BE VERY GENTLE on the 
drill. Constantly check its perpendicularity. Don'n drill without constantly
lubricating the bit/stud. It likes to walk off the heat treated stud into 
the soft Al. If it happens, though, dont panic. There is an easy way out, 
I'll tell you what to do if it happens.

5. Don't use the square Craftsdude easy outs, very brittle. I snapped that 
hard, high carbon content sucker in the forged stud FLUSH! One week and a 
special milling tool later, that I had to make for that purpose, I've 
managed to take it out. Use real industrial grade stuff. I used a spiral 
Edwin set.

6. Get all the parts beforehand: new gaskets and all. 
Actually, if you wish, I can e-mail you a list of parts/# needed. I maintain
a detailed MS Access database on my car's repairs.

Dont sweat it, pretty routine stuff. Think of it as an essential part of 
Audi ownership.
E-mail me if something goes wrong. I can probably perform this repair 
blindfolded now.

Good luck! :o)

Igor Kessel
'89 200TQ, chipped and MOMO'd through out,
in Tornado "arrest-me-officer" Red;
'88 Fox, "the FOX machine";
ex '85 5000s, "the EE's nightmare"
Phila PA, USA
a6561TB@gnn.com