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Exhaust manifold studs corroded beyond use

Discussion in 'Early CJ5 and CJ6 Tech' started by russo, Jan 2, 2012.

  1. Jan 2, 2012
    russo

    russo Hope is not a method

    Norris, Tennessee
    Joined:
    Oct 28, 2005
    Messages:
    498
    I have been pulling my exhaust system for replacement, and have discovered that the studs in the right side manifold have corroded to the point that they have no threads left. The nuts are also fused to the studs. I have used Kroil and heat as well as a variety of SAE and metric sockets in an attempt to remove the nuts - to no avail.

    I guess I need to remove the studs from the manifold and replace them. What is the best way to approach this? Should they twist out?

    TNX
     
  2. Jan 2, 2012
    Stout

    Stout Member

    Quakertown, PA
    Joined:
    Nov 1, 2010
    Messages:
    958
    If you are lucky, the studs will come out with the nuts attached (like a bolt) and then you can just replace the studs. If you are unlucky like I am then they will break and you'll have to drill them out and possibly have to use a Helicoil as a replacement. Just keep applying penatrating oil and let it soak. You may also try applying heat with a torch. If you have access to an impact gun then that would be your best bet.
     
  3. Jan 2, 2012
    russo

    russo Hope is not a method

    Norris, Tennessee
    Joined:
    Oct 28, 2005
    Messages:
    498
    I assume the studs twist out in the same direction as the nuts? So, if I can get a bite on the nuts the stud should eventually come lose or break?
     
  4. Jan 2, 2012
    Stout

    Stout Member

    Quakertown, PA
    Joined:
    Nov 1, 2010
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    958
    That is correct. Hopefully they will not break on you. Again, if you have access to an impact gun I would use it.
     
  5. Jan 2, 2012
    timgr

    timgr Jeepin' Nerd 2020 Sponsor 2019 Sponsor

    Medford Mass USA
    Joined:
    Aug 10, 2003
    Messages:
    20,570
    You can try a muffler shop to remove any broken studs. In my experience, they can blast the stud out of the manifold with their cutting torch.
     
  6. Jan 2, 2012
    russo

    russo Hope is not a method

    Norris, Tennessee
    Joined:
    Oct 28, 2005
    Messages:
    498
    Thanks much. That may be what I end up doing - after I try all else :)
     

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