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Thread: Snapped exhaust manifold stud, Also snapped EZ Out

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    Snapped exhaust manifold stud, Also snapped EZ Out

    Hey All,

    The rear top manifold bolt snapped about 2mm inside the head when removing the manifold on the weekend, drilled out the stud and when removing also snapped the EZ out inside the thread 😑. I know this is a nightmare as ive spent the last two days trying to redrill and get a new centre but because of the hardend steel its been difficult and pushing my drill holes to the side. Ive managed to get the hole recentered and slightly larger but i cant get any depth in this new hole and blunted 10 brand new 3mm drill bits.

    Ive tried a new set of ez outs different from the ones is snapped, theyre left hand spiral self tappers but cant get a deep enough drill hole for them to bite.

    Have anyone got any ideas as im scared to keep at it with drill bits that dont go nowhere and i dont want to butcher it more than i already have.

    Thinking its best to take it to the local exhaust place and get them to look at it? Thats probably my sadest bet right? Couldnt find any mobile local tread specialist in the Liverpool NSW area. And dont really want to remove the head if i dont absolutely have too.

    Cheers

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    growler2058 (12th June 2017)

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    Oh man sounds like a nightmare. Weld a nut on is a good bet but probably not if it's 2ml deep. . . Arrrrgh! !

    Yeah hate easy outs they're anything but easy at the best of times. .

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    EZ outs are brittle so if you can use a punch to shatter what is left in the hole. The guts of an old injector are great for this sort of thing.
    Then you need a guide to keep the drill bit straight. A bolt the same diameter as the stud with a hole drilled down the centre with the drill bit your going to use. Trim the length of the bolt so about 10mm of the drill sticks out. Wind a nut down the bolt to the thickness of the manifold flange.
    Put the manifold back on, put the guide into the hole in the manifold and drill.

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    Quote Originally Posted by Turtle_au View Post
    EZ outs are brittle so if you can use a punch to shatter what is left in the hole. The guts of an old injector are great for this sort of thing.
    Then you need a guide to keep the drill bit straight. A bolt the same diameter as the stud with a hole drilled down the centre with the drill bit your going to use. Trim the length of the bolt so about 10mm of the drill sticks out. Wind a nut down the bolt to the thickness of the manifold flange.
    Put the manifold back on, put the guide into the hole in the manifold and drill.

    Sent from my SM-T355Y using Tapatalk
    And use a sharp/new drill even worth buying a couple especially if there are still small bits of the hardened EZ out in the hole.
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    Don't know if it'll work or not.

    Drown it in wd40 a few times over a few hours then try to turn the remaining stud with a hammer and punch.

    This is the only reason why I still haven't changed my 20 year factory exhaust at home.

    Good luck..

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    I think you have two choices.

    1)Buy one of those diamond cylindrical grinding bits to fit the hole and grind off the broken stud & EZ out bit slowly(use oil or water to deal with the heat and avoid ruining the grinding bit).
    Diamond grinding bits are not that expensive. Fleabay have them.

    2)Use a diamond or HS steel hole cutter of the same diameter or slightly smaller to cut into the broken stud and then use a pointy puncture bit to break it or simply pull the stud out once the cut is deep enough.

    Either way, you're looking retappin the head and use a bigger stud, helicoil, etc.
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    for future try this style of extractor it works better https://www.ebay.com/p/Neiko-04200A-...d=261659054019
    its how i got my broken exhaust stud out.

    how much of a rush are you in? i'm not that far i could grab some gear and take a look on the weekend
    if its worth doin its worth over doin

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    I had a similar problem with a water pump stud i ended up get some hardend drills , very expensive

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    Got it sorted, decided to go with the expensive way out and get a professional out to remove the stud, wasnt cheap but the job is done cleanly with no helicoil needed. I wont be using those left hand spiral type of EZ outs again thats for sure!

    Thanks everyone for your help, i'll be alot more careful when it comes to removing my next broken stud.

    Any thing i should know when putting new studs back in? i know the torque setting for the nut when the manifold goes on, but is there one for the stud?

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