broken y pipe exhaust bolt

super1c

super1c

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Sep 15, 2003
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Freeland & Otsego lake, MI
Trying to get y pipe off exhaust and the nuts are rusted bad. I just snapped off a stud. Its not flush with jug so i can get vice grips on it. What are my options for fix. Does that stud come out? Any help on this one would be great. Chris
 
Spray the stud with penetrating oil and give it time to soak.
If worse comes to worse you will have to drill it out and chase the threads and re-install a new stud.
 
My experience is to repeatedly heat the stud, then spray it with a penetrating oil. I do this several times allowing the oil to penetrate for 10 min. in between heat cycles. Patience and repeated heat-oil cycles are your friends!!!!

This should work but if it does not, the next method I would recommend is to take the cylinder off the engine so you can get full access to the broken stud with a drill. Carefully center punch the center of teh stud, drill it for an easy-out then use the easy-out while using teh heat-oil process.

If the above does not work, then you will have th drill out the stud and retap the hole. We I have had to restort to this process, I use left-hand twist drill bits. Move up 1 drill size at a time. This process requires you to drill on the CENTER of the stud, if not you will damage the the threads in the cylinder. I use left hand drills since I have found when the broken studs/bolts will spin out freely once I have drilled it close to the stud diameter.

If you want, for no charge other than the cost of return shipping, you can send me the cylinder and I will remove the broken stud.
 
stein700sx said:
Lefty loosey ,,righty tighty
Click to expand...
X2. The stud is just like a bolt only threaded on both ends. When you are ready to install the new stud use a double nut and thighten into place.DO NOT USE VISE GRIPS TO INSTALL THE NEW STUD - bevause your fellow TYers won't let you be a HACK....
 
Thanks guys, have to work a long weekend so i wont get at it now till next week so i will be spraying it down daily with pb blaster maybe a little heat as time alows. Then will start from there. If i cant get it out i will take you up on your offer rx1jim for sure. This is on my daughters project viper and some of the rust is starting to get the best of us. But it will not defeat us! Thanks for the quick reply's, will post back with results. Chris
 
the best method i have found is to first weld a washer to the stud then weld a nut to the washer and out it comes. this year i found a broken cylinder stud, got it out without removing the cylinder using thr welder trick.
 
As suggested above, welding a nut on works very well and is quick if you have access to a welder. Heat cycling it as also mentioned above work too, but takes more time. It helps if it gets very cold between heat cycles. The aluminum will expand faster than the bolt. I have been using Jig-a-loo instead of PB Blaster for a while now as it seems to work better. It is best to make one serious attempt at it - avoid trying it little by little as the vice grips will keep taking material off the bolt stub.
 
Took a look at my broken stud today before work. 2 questions. When heating should i heat the stud or the jug around the stud? I think the aluminum jug will expand faster then the stud correct? Also i really dont have much room to get a set of vice grips in their on the stud. I am able to thread a bolt onto the stud but no access to a welder. Is their anything i can use to keep the nut on the stud so i can back it off with a socket? Jb weld on the threads? Also if i do pull the jug to get at it better i can just clean the gasket real good and reuse it right. Dont want to tear down the whole top end over this broken stud. Any thoughts guys? Chris
 
Heat the jug with expanded heat source (like a heat gun). Yes the goal is to expand the jug more than the stud. Sometimes heat cycling helps but on a exhaust bolt this already happens as it is run. If you can get to it right after it was run it is usually easier, but I doubt you have that option now.
 
Well got the stud out. I ended up having to take jug off and a brother of a friend works at a machine shop. He got it out for me before i could get home from droping it off. I made a joke that at least he could have made it seem like it was hard to get out. Welded a nut on the end and a lot of heat. Got the jug back on hope i did it right. Thaks for the help guys. chris
 
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