TD5 Turbo - Downpipe nuts seized solid. Any ideas?

bankz5152 · Nov 9, 2016

Trying in vain to fit my decat pipe for 3 days now!

Studs/nuts have been sprayed with PlusGas every day for a week - Nothing

Ran the engine up to temp, still no joy.

Hitting a spanner with a hammer. Nothing!

Ive ordered some nut splitters but any ideas to try before they arrive?

There is access to drill two studs out (if needed) but the third remains stuck.

Cheers

jamesmartin · Nov 9, 2016

bankz5152 said:
Trying in vain to fit my decat pipe for 3 days now!

Studs/nuts have been sprayed with PlusGas every day for a week - Nothing

Ran the engine up to temp, still no joy.

Hitting a spanner with a hammer. Nothing!

Ive ordered some nut splitters but any ideas to try before they arrive?

There is access to drill two studs out (if needed) but the third remains stuck.

Cheers

problem with nut splitters is they arent very good with flange nuts,which down pipe nuts are , i use a long extension/s and a breaker bar from underneath

The Mad Hat Man · Nov 9, 2016

jamesmartin said:
problem with nut splitters is they arent very good with flange nuts,which down pipe nuts are , i use a long extension/s and a breaker bar from underneath

what nut splitter do you use, James?

jamesmartin · Nov 9, 2016

The Mad Hat Man said:
what nut splitter do you use, James?

generally a sharp chisel and a decent ball peen though i do use this type

The Mad Hat Man · Nov 9, 2016

jamesmartin said:
generally a sharp chisel and a decent ball peen though i do use this type
View attachment 110423

Ta James
I have one of these (Hydraulic)..... and its bloody useless

.

Brown · Nov 9, 2016

Yes, I had trouble with these when I changed my exhaust. Yes, they've typically got built in flanges and I didn't want to snap the studs off, because they're made of tough stuff and would be hard to drill out. I cut the nuts off with a junior hacksaw. it took a while, but was less time consuming than the alternatives such as snapping the studs accidentally, or taking the manifold off the engine. On reassembly I used ordinary nuts so next time I can just pop a nut splitter on.

The Mad Hat Man · Nov 9, 2016

wots wrong with using brass nuts?

bankz5152 · Nov 9, 2016

jamesmartin said:
generally a sharp chisel and a decent ball peen though i do use this type
View attachment 110423

Exactly what I have ordered.

I havnt got an extension that long but ill have a look see how much they are, or if a mate has one. Slowly going with a Jr hacksaw aint a bad shout either.

Refitting with brass nuts is a bloody good idea though! Got a new turbo en route which will be fitted, so may see theres any chance of undoing the Turbo/Exhaust manifold nuts and either dropping the whole thing down or if theres space pull the down pipe through the engine bay. Failing that manifold off, buy a new one and refit all brand new stuff with brass nuts hoping the manifold studs do not break in the head...

While we are on this subject what is the best way to remove the manifold studs from the head? I bought some Wurth ones which I would ideally like to fit.

jamesmartin · Nov 9, 2016

bankz5152 said:
Exactly what I have ordered.

I havnt got an extension that long but ill have a look see how much they are, or if a mate has one. Slowly going with a Jr hacksaw aint a bad shout either.

Refitting with brass nuts is a bloody good idea though! Got a new turbo en route which will be fitted, so may see theres any chance of undoing the Turbo/Exhaust manifold nuts and either dropping the whole thing down or if theres space pull the down pipe through the engine bay. Failing that manifold off, buy a new one and refit all brand new stuff with brass nuts hoping the manifold studs do not break in the head...

While we are on this subject what is the best way to remove the manifold studs from the head? I bought some Wurth ones which I would ideally like to fit.

2 m8 nuts locked together

neilly · Nov 9, 2016

Which ones did you order? for future reference.

removing studs, I normally try to nuts locked against each other and then unwind it.

Cheers

jamesmartin · Nov 9, 2016

bankz5152 said:
Exactly what I have ordered.

I havnt got an extension that long but ill have a look see how much they are, or if a mate has one. Slowly going with a Jr hacksaw aint a bad shout either.

Refitting with brass nuts is a bloody good idea though! Got a new turbo en route which will be fitted, so may see theres any chance of undoing the Turbo/Exhaust manifold nuts and either dropping the whole thing down or if theres space pull the down pipe through the engine bay. Failing that manifold off, buy a new one and refit all brand new stuff with brass nuts hoping the manifold studs do not break in the head...

While we are on this subject what is the best way to remove the manifold studs from the head? I bought some Wurth ones which I would ideally like to fit.

the nuts are flange nuts a splitter wont help, can you borrow a few long extensions to make one long one

bankz5152 · Nov 9, 2016

Bloody hell I missed that bit... Possibly ill have a hunt around see whos got what.

Having a look on ebay looks like I can get a de-webbed, de-stressed TD5 manifold for £160 or so, doesn't seem too bad. Carefully remove the manifold nuts and pull the whole thing through the engine bay, cut the down pipe in half if need be (I have a spare incase of MOT issues etc...)

jamesmartin · Nov 9, 2016

bankz5152 said:
Bloody hell I missed that bit... Possibly ill have a hunt around see whos got what.

Having a look on ebay looks like I can get a de-webbed, de-stressed TD5 manifold for £160 or so, doesn't seem too bad. Carefully remove the manifold nuts and pull the whole thing through the engine bay, cut the down pipe in half if need be (I have a spare incase of MOT issues etc...)

if you can undo all the manifold nuts without snapping a stud you will have done well , i usually end up drilling and extracting a couple

bankz5152 · Nov 9, 2016

Seeing as the turbo has to come off anyway... Ill see whats easier to do, Turbo/Manifold or Block/Manifold. Then deal with manifold warping as and when it happens, never had that issue on my 90 however.

Cheers guys.

Brown · Nov 9, 2016

The exhaust pipe comes off downwards, but you need to get the anti roll bar and the removable chassis crossmember out of the way. So a few more reluctant nuts and bolts to undo. I think I saw a two piece exhaust advertised somewhere that could be separated so you didn't have to do so much dismantling.

bankz5152 · Nov 9, 2016

Ive done it before on my 90, even though that was older it was a hell of a lot less stuborn!!

No ARBs to worry about and the center X member bolts move, already tried those. Though considering there is some pretty bad rust in areas I may drop it just to check, maybe.... lol

I know it comes off downwards, though current thinking is try the Turbo/Manifold bolts, see if they move. If the do, great, then take a grinder to the down pipe and pull it out the top/bottom. Drop the Xmember and fit the new turbo + decat.

Brown · Nov 9, 2016

Yes, when I took mine apart there was a lot of rust between the bolt-in crossmember and the chassis, so it's worth taking it out and getting some rust proofer or paint in the joints before it makes holes in the chassis.

bankz5152 · Nov 9, 2016

Yeah im hoping it will be alright. My 90 is solid, inc under there!

bankz5152 · Nov 10, 2016

Just thinking today, if removing the whole manifold, im guessing i've got to disconnect the top coolant hose, any suggestions on how to stop it dumping coolant everywhere?

flat · Nov 10, 2016

bankz5152 said:
Just thinking today, if removing the whole manifold, im guessing i've got to disconnect the top coolant hose, any suggestions on how to stop it dumping coolant everywhere?

Hose clamps before you undo, then try with a pot to catch what comes out. Then bend the rubber pipe back out te way. For extra piece of mind if your going to move and wiggle a lot of stuff is put something in te end of the pipe (wooden dowel or similar) and jubilee clip it. Should be okay with just pipe clamps though, clamp all your pipes that you can to prevent pressure from water in one area coming out somewhere else.

You will loose some but should be able to minimise it then you can just top up later

TD5 Turbo - Downpipe nuts seized solid. Any ideas?

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