Re: broken head stud

[drew <drew@dyermaker.cs.uoguelph.ca>]

I assume you mean one of the exhaust manifold studs that are in the head?
These can be removed with the engine in the car, but it's an unpleasant
job.  If the studs is broken off flush or inside the head (what I usually
see on JH engines, especially on #1 for some reason) then the following
will work:

A right-angle drill (air tool) will make the job a hell of a lot easier,
but if you have a fairly small electric drill that you can get between the
head and the firewall then that will work too.

You'll also need a good quality screw extractor kit (years ago I spent
about $30 CDN on a 5-piece kit and have never regretted it as I haven't
broken an extractor yet (KOW))

Remove the exhaust manifold and the intake too to make it easier to get in
there, especially if it's an upper stud.

Using a sharp centre-punch mark the centre of the stud and drill a small
pilot hole straight down the centre of the stud (this is the tricky part
- you want to be true here or else you'll drill into the head when you use
a bigger bit)

You next want to drill out to the size of the extractor that you'll use.
I'm afraid I don't remember what size drill bit I use, but you generally
want something that is between 50% and 60% of the size of the stud (8mm)
With care you should be able to drill down the length of the stud (there's
a small space at the bottom of the hole in the head, so you'll feel it
when the drill drops into this space, if you're gentle with the bit.  Use
a mirror as you're drilling to ensure that you're drilling in at a right
angle, as you don't want to drill into the head.

When your second hole is drilled, drive your good-quality screw extractor
into the hole with a hammer, and turn the stud out (you want to chose a
suitably sized extractor that will get the most 'bite' in the stud.) By
the time you've drilled the stud, the vibrations and the heat will likely
have loosened up the threads, by the time you've driven in the extractor,
then they should be loose for sure, and that stud will back out with
little or no trouble at all.

I've used this procedure countless times now (usually while the engine is
out of the car, which makes it much easier) and it has never failed.  Just
remember to use a good-quality screw extractor - if the extractor should
break off in the stud, you're sunk!

HTH,

Drew (84 Wolfsburg Ed.)

On Mon, 2 Apr 2001 Scirocco2l16v@aol.com wrote:

> My brothers car doesn't want to be fixed.  I got a rear for the car (thanks to Peter in Del.) put it in this weekend.  But when I went to do the exhaust manifold, I noticed that one of the head studs was broken in the head.  Is there anyway to get the stud out without taking the head off?  Thanks for the help so far.  The car will be on the road soon, I hope....
> 
> -Dave Kirsch
> 
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Drew MacPherson, Network Analyst, University of Guelph

drew@dyermaker.cs.uoguelph.ca           |  visit the Massey-Harris page:
http://dyermaker.cs.uoguelph.ca/~drew   |  http://m-h.cs.uoguelph.ca


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