Stupid turbo manifold studs!!!!

[zandrew]

While removing the stock turbo manifold 2 of the studs broke. I am in the process of removing the gt2560r Elim from 2001 and installing it in my 99.5. I will then upgrade my 2001 to gtx2867r. The problem is it currently has 2 broken studs and yes it is my project. I plan on removing it's engine and building it with the components I have been saving for 99.5.

The studs that broke is a concern but I think I got lucky. They are on the top row and second from the outside on both ends. Has anyone ran a head with missing manifold studs? If so any issues?

Thanks

[b6Hate4]

It would take a real set of balls to do it but I would Dremel it flush with the head, counter sink it then drill it out, followed by a helicoil tap.

Though you could attempt to run it without those studs, but you would be in that same boat if the method I mentioned fails. Might as well give it a shot.


Sent from toilet stall #4

[Seerlah]

Any way to meticulously tac wels something onto the stud so you can thread it out? You are a machinist by trade. Honestly, not quite sure how you were able to snap those studs. But FWIW, I have successfully heli coiled one of those holes in the past. I would not run the manifold with a missing stud, though. What happens is if you run enough air, possibility that the leak where missing stud would be will manifest into a warp.

[MetalMan]

When I pulled the stock manifold off my 2001, I opted to replace all of the studs. Most of the threaded holes in the head were chewed up a little bit (it took vice grip pliers to remove most studs...). Had to clean up all the threads with a tap. New studs went in with the high-heat antiseize 034 sells.

[zandrew]

Mine snapped off below the aluminum of the head. I think they were replaced as it's a 2001 (awm? Don't know engine code) with an aeb head. My guess is they were replaced with crappie versions and someone did not use anti seize. Machining can not get them out but if I can get them out I can recap for a larger size and use a step down stud. Ideal would be getting them to come out and replacing them.

I am hoping I can weld something small to the studs and then weld a nut to it. I was wondering if this was something others have had happen and said screw it and ran it as is.

[Royal769sr]

Any way to meticulously tac wels something onto the stud so you can thread it out? You are a machinist by trade. Honestly, not quite sure how you were able to snap those studs. But FWIW, I have successfully heli coiled one of those holes in the past. I would not run the manifold with a missing stud, though. What happens is if you run enough air, possibility that the leak where missing stud would be will manifest into a warp.

THIS.. do not run without a stud. Get that thing out and replace it.heli coil if need be

[Davdraco1]

I replace all my studs with Allen head bolts. I have the FT manifold and with it being larger the aliens helped a lot

[Davdraco1]

I replace all my studs with Allen head bolts. I have the FT manifold and with it being larger the aliens helped a lot. I can't amazing using studs with the larger manifolds.

[zandrew]

David I can understand the Allen bolts being easier to install (aka socket heads) but the head being aluminum it's not the best idea. The stud is used in aluminum since you install them without tightening in the aluminum itself. You tighten the nut which pulls the stud (tension) against its tapped threads sharing the torque load evenly across both sets of thread. With a bolt you are doing both torsional and tensional forces which will Gall the aluminum. It may not cause issues at first but if you have to remove them down the road it's best to go back to studs.

So the consensus is to replace the studs and not run it minus the 2 that's missing. I have to pull the head anyway so I will fix it once it's out.

More issues from a car....

[MetalMan]

I agree with zandrew about not using bolts in the aluminum threads. It's kinda asking for trouble. However if the holes had helicoils installed, then it would be no problem.

[Davdraco1]

Shit, I never knew about not using bolts. Hopefully the only time they come out an EFR will be going in.

[chris164935]

I've had the studs break in the head before. The machine shop I took my head to was able to get them out without any issue. After that, I bought a set of stainless ARP studs. The machining of these studs and nuts are amazing. It makes taking the manifold off a dream. Break the nut loose and then spin it off with your fingers easy. Definitely worth the $100+ I spent for the set. If you buy a set, you'll end up with extra because they don't sell sets of 13. I used the extra studs for ground locations on the block (one for the starter and the other for a new ground location I did under the intake manifold).

[vrmm]

Maybe I'm more on the lazy side of this forum, but I've been missing 2 intake and 2 exhaust studs for the last 8 months and have not had any problems running 15 psi or 35. I bought the head like that and just put a new gasket on and called it good. Like you it is not an outer nut or bolt. I have checked like twice to see if I could see ex leaks on the head and have yet to see one. I'm not telling you to not fix it... Just answering you with 'yes it's been done with no catastrophic failure following'.