Re: IML: Problem with exhaust manifold studs...

[Benjamin Breyer <bmb2102@xxxxxxxxxxxx>]

If you reinstall the manifold with four bolts, use two gaskets.

Pulling the head is the safest way to deal with this problem. If the
job makes you nervous, let a machine shop extract the studs. It
isn't that difficult, however. Use a *good* drill bit set, starting
small, and gradually step up the bit size until little more than the
stud threads remain. Then use an E-Z out, need nose pliers, or
something else. If you measure the depth of the stud hole, you
needn't fear drilling too deep. You will probably feel the bit
bottom out before you begin drilling into the head anyway. I've
never used them, but a left-hand drill bit set might be a good way
to go.


Quoting Rob van der Es <r.vdes@xxxxxxxxxxxxxxx>:

> Hi Paul and the rest of the IML gang,
>
> I need some expert advise with regard to the exhaust manifold
> studs of my
> 1960  Imperial.
> For 10 days ago I broke the exhaust manifold flange of the left
> manifold...
> I noticed a a roadbump too late and was hitting it with too much
> speed,
> since the whole exhaust system is pretty rigid the impact was
> given
> directly to the cast iron manifold..
>
> With the restult that the flange has broken..
> I found myself a reputable cast iron welder that has done the job
> many
> times before so with a little luck I will have my manifold back
> early next
> week.
>
> But now for the real problem: when taking the manifold off two
> studs were
> broken....
> Despite of several overnight soaking sessions with penetrating
> oil!
>
> The number two stud (counting from the radiator) and the last
> stud are
> broken and almost flush with the head.
> Ofcourse I can try if the 4 remaining studs and bolts will secure
> the
> manifold but  I simply don't like the idea.
>
> On the otherhand, I either don't like the idea of taking the head
> off.
> And at least the last stud is very difficult (or not..)
> accessible with
> the head in place.
> So maybe I should aim for the second stud to come out.
>
> Both studs are almost flushed with the head surface (slightly
> below
> actually).
> Is there a safe way to get them out?
> Or should I try to secure the manifold with the 4 remaining nuts
> and see
> what happens?
>
> If this doesn't work out, how do I remove those broken studs
> then?
> And where can I buy new studs for my engine?
>
> Ofcourse I can try to drill out the number two studs since I
> think I can
> access this one from the left front wheel area (with the left
> front wheel
> removed ofcourse).
>
> But what if I screw up and the studs doesn't come out, since
> these studs
> are in the cooling fluid area it is important that I don't cause
> any
> leakage.
> If I break a drill for e.g. while it is just through the center
> of the
> stud (if I am lucky..) and the broken part gets stuck, cooling
> fluid will
> escape then!!
>
> So should I go for the 4 studs fasting method first?
>
> Any words of whisdom??
>
> Thanks,
>
> Robert
> 1960 Imperial Crown
>
>
>
>
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