broken exhaust manifold stud

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  #1  
Old 06-29-05, 07:58 PM
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broken exhaust manifold stud

Any suggestions how to get out this broken stud on the aluminum head of a 3.1L 3100 engine. There is about 3/16" of the stud sticking out but vise grips slips off all the time. I've drilled the center of it with a 1/8" bit and tried an extractor (#2) but the extractor has broken off inside and cannot get it out. Would I be able to heat it up with a small torch or something without damaging or warping the head or gaskets. The head is already installed on the block and I don't want to take it off again (the front one by the Rad)

Thanks,
Al
 
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  #2  
Old 06-30-05, 06:06 AM
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No heat on aluminum. Save yourself additional headaches, get it off and to the machine shop. It will likely need to be drilled and a helicoil installed.
 
  #3  
Old 06-30-05, 09:41 AM
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I like to cut a slot in what's left and turn it into a flat head screw
But I think it's too late for that with this one
I think this one's headed for the machine shop
 
  #4  
Old 07-01-05, 06:48 PM
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Location: Minnesota
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I have used heat with great success. What I would do is get a nut that will go over the broken stud. Hold the nut tight to the aluminum and put a good weld to the nut and stud. Take a torch and heat up the area around the broken stud. Use some common, sense don't get it so hot that the aluminum melts or you warp something. Do not try and take the stud out when the aluminum is hot. Wait until the aluminum has cooled down so cold that you can put your hand on it or make ice cubes. Then turn out the stud. Aluminum and steel heats and cools at a different rate. The two pieces of metal will break loose of each other while they are cooling. And if you wait till they are completely cooled you will not take the aluminum threads with your stud. I have done this to remove a spark plug from an aluminum head (air cooled) Done the same thing to remove studs that were broken off flush on a aluminum swimming pool piece. The two guys who were helping me were amazed that I could do that. Another time we were trying to get the aluminum end out of a hydraulic cylinder. The cylinder is steel so we heated that up then tried to remove the plug, no success. We then heated it up hotter and tried to remove the plug, no luck. We then stopped for lunch, when we came back the cylinder was cold to the touch. We took our homemade wrench put it on the plug and turned it out with no effort at all.
 
  #5  
Old 07-01-05, 07:14 PM
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I too have done this with no problems. But when I welded the nut on, that heat generated from the mig was enough to free up the stud.
 
  #6  
Old 07-04-05, 07:30 AM
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Thak you to all who replied. I got it out Saturday morning with my uncles help and a wire feed welder. After unsuccessfuly trying to weld on different nuts by filling the hole with weld we finally got it by building out the weld on the broken stud then welding a bolt on the end of that. Finally!!!!!

Al
 
  #7  
Old 07-04-05, 07:57 AM
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Sweet!
I'll have to try that sometime...
Like this afternoon
Yeah I broke a stud
It's in an aluminum housing
Grrrr....
I'll have to fire up the wire feed welder and see if it still works
Thanks
 
  #8  
Old 07-04-05, 04:59 PM
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Location: Cape Cod
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Got mine out with a Lisle #19250 Stuck Bolt, Nut, & Stud Remover
Drove it onto what was left and put a wrench around it
Came right off
 
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