Reev said:

Hiya guys and gals, I have a td5 discovery with 15p engine. I have a snapped exhaust manifold stud, I've got a new set of studs and gasket ready to do the job, I just wounderd if anyone knows what I'm letting me self in for? What sort of job it is to do as I have limited time so need to plan things, I know every job is different but if generally they are simple to strip down etc. Any comments welcome things to look out for etc as I'm new to the td5 regards Reev

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Kwakerman said:

Has it snapped off flush or below the surface of the head or is there some stud remaining to get hold of? If the remnants are well stuck in and you can't get it out then it is possible to get it spark eroded out. I've had it done before with an installed (different) engine but don't know if there would be sufficient space on a TD5. If you are going to try and drill it and use an extractor buy a decent one, last thing you want is a broken extractor stuck in the remnants of the stud

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Reev said:

Thanks for that, I think it's almost flush, its the bottom front one so not in plain view, I have decent extrators (snapon) and no I know the joys of snapping them.
I'm new to the td5 engine only had it for a few months so not worked on it yet, I've had me share of 200 and 300 discovery's.
I'm just worried about getting into it and it turning into "one of those jobs" as time is against me at the min, but very reluctant to pay someone to do what I can do me self.

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Kwakerman said:

Much like yourself I detest paying someone to do something I could do. I'll even buy specialist tools to do a job myself instead of paying others even if the overall cost would end up similar as at the end of the day I then have another tool ready for next time. It's one of those balancing acts if you are short of time, pay up for a quick job or save money and take longer. Ps you also need to look in to why the stud snapped, I'm aware there are TD5 manifold warping issues so you may need a new manifold or get your one skimmed or the webs relieved. Do a search for TD5 warped manifolds although others may have better info

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FlyingPete said:

Look into using left-handed drills as an alternative to extractors. The idea is that the reverse rotation allows the cutting faces of the drill to apply torque which undoes the stud. If you have no luck, then you've drilled the stud out anyway.

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Kwakerman said:

Much like yourself I detest paying someone to do something I could do. I'll even buy specialist tools to do a job myself instead of paying others even if the overall cost would end up similar as at the end of the day I then have another tool ready for next time. It's one of those balancing acts if you are short of time, pay up for a quick job or save money and take longer. Ps you also need to look in to why the stud snapped, I'm aware there are TD5 manifold warping issues so you may need a new manifold or get your one skimmed or the webs relieved. Do a search for TD5 warped manifolds although others may have better info

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Reev said:

Yes I agree I need to look into why the stud snapped I am hoping it's just fatigue as my disco is high mileage 218k almost.
I believe that the warping problems is the inlet manifold not the exhaust but I may be wrong on this.

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