Exhaust Studs

che57vy · 02-25-2020, 02:13 PM

Doing the maintenance today on my 2009 Greyhawk found the dreaded snapped exhaust studs. I see at least three. I usually do repairs myself but do not see how I can even get at the studs, this is going to be $$$$

**Midnightmoon** · 02-25-2020, 02:48 PM

A little trick I learned a while back, once you get access to the manifold, drop a little bead of weld from a Mig or wire feed welder on top of the broken stud. Build it up until you can tack a nut on the end and turn it out with a wrench or pair of channel locks.

gymracer · 02-25-2020, 03:38 PM

That will work if you can get to it. Did that on my 2500HD 6.0 truck, got out 3 of 4 broke. Had to drill and heil-coil the other one. Had a C class on a 450 Ford and it first broke one I fixed, then 4 more. Was impossible to get to those. Main reason I traded it.

che57vy · 02-25-2020, 05:19 PM

I was told best way is cut nuts off leaving studs then using a stud extractor they may twist out. As said above weld nut on others. I was almost tempted to trade it.

Colorado · 02-25-2020, 09:08 PM

Typically the studs rust or freeze in the manifolds not the block. If you’re going to attempt this repair on your own, start spraying everything down with a QUALITY Penetrating lubricant: PB blaster or Kroil. If the bolts do break off they tend to break off in the manifold, leaving plenty of bolt left to weld a nut too. Any of the bolts that break off, spray them with a penetrating lubricant for several days, and use an easy out or welding nut to them and remove them.

gymracer · 02-25-2020, 09:59 PM

The ones on my V10 broke off from heat and the stud fell out leaving the threads in the head. Just getting the manifold off was going to be major. Good reason to trade. My Chevy truck broke the heads off leaving enough stud to weld a nut to and they came out easy.

che57vy · 02-26-2020, 09:15 AM

I saw a post that Ford put out a bulletin that techs reparing studs were supposed to enlarge the rear manifold holes for expansion

gymracer · 02-26-2020, 11:17 AM

That figures, mine broke rear ones first.

che57vy · 02-26-2020, 04:52 PM

they all seem to break rears first, from now on I am going to let her idle for a while after a long run.

Braz · 02-26-2020, 06:37 PM

Quote:

Originally Posted by che57vy

they all seem to break rears first, from now on I am going to let her idle for a while after a long run.

How does that help?

che57vy · 02-27-2020, 08:16 AM

supposed to cool engine components, it is recommend on my tractor according to manual if your using it hard.

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