My exhaust manifold started to blow tonight and I'm away with the caravan on weds so I "whipped" it off and yes 1 and 5 were goosed! Now I'm going to get a new gasket tomorrow and I have a with stud set coming tomorrow but I'm worried about the possibility of snapping the studs off trying to get them out? Is this likely? Should I just use my existing studs for now since I'm on a deadline or do they come out fairly easy and its the manifold that normally snaps them?

Thanks

A new gasket alone will not do the job. The manifold has blown because it warped, so you need to get the manifold skimmed before putting it back on.
If the studs did not come out when you removed the nuts, then they may be pretty firmly fixed. A stud removal tool or two nuts locked together may work, but be really careful you do not snap them. If they are in good shape I would be tempted to re-use them with some brass nuts to reduce the chance of the nuts seizing in the future.

To clarify, what normally snaps the studs is the action of trying to undo the nuts. If the nuts are seized you may find that you apply enough torque that the stud snaps before the nut unscrews. Wurth studs are good replacements as the torque required to snap them is massive.

Hi robhtid, I did my sons 04 TD5 about three weeks ago, of the two broken studs on No 1 cyl. one had to be centre drilled & re-tapped to 8mm as it wouldn't budge with an easy out & I didn't want to break it (the easy out), the other one as soon as I started to centre drill it wound itself in so that came out very easily with the easy out. On the No 5 cyl. one stud hole was already stripped so I had to drill & re-tap it to take a 10mm stud which was used on the 300 TDi ex. manifold. He had the manifold skimmed & we fitted a Wurth uprated stud kit which came with all the gskts. needed. The remaining seven studs came out without a problem using a 8mm stud removal socket. Reading on here, some come out easily & others need a bit more attention (drilling). You'll probably find some of the remaining studs will come out with the nuts seized to them, hopefully all of them, which is great & the rest will need a stud removal tool (you might be able to lock to 8mm nuts together on the stud & get it out that way). If you do end up drilling them make sure you measure the depth of the stud hole in the head & mark you drill bit with tape as you don't want to go any deeper than you have to. Good luck. Use heat on the nuts if you can.

Si Click said:

A new gasket alone will not do the job. The manifold has blown because it warped, so you need to get the manifold skimmed before putting it back on.
If the studs did not come out when you removed the nuts, then they may be pretty firmly fixed. A stud removal tool or two nuts locked together may work, but be really careful you do not snap them. If they are in good shape I would be tempted to re-use them with some brass nuts to reduce the chance of the nuts seizing in the future.

To clarify, what normally snaps the studs is the action of trying to undo the nuts. If the nuts are seized you may find that you apply enough torque that the stud snaps before the nut unscrews. Wurth studs are good replacements as the torque required to snap them is massive.

Click to expand...

Hi, yeah them Wurth kits seem good, the one my son got came with copper nuts. My 01 TD5 has the same problem (two broken on No1 & one on No5) so I too will get the Wurth kit when I do mine & as you say get the manifold skimmed as well. Happy days!

Thanks, I'll leave the studs be for now as they are all solid at the moment. Sorry I forgot to mention my first job today is to get the manifold skimmed!

Si Click said:

A new gasket alone will not do the job. The manifold has blown because it warped, so you need to get the manifold skimmed before putting it back on.
If the studs did not come out when you removed the nuts, then they may be pretty firmly fixed. A stud removal tool or two nuts locked together may work, but be really careful you do not snap them. If they are in good shape I would be tempted to re-use them with some brass nuts to reduce the chance of the nuts seizing in the future.

robhtid said:

Thanks, I'll leave the studs be for now as they are all solid at the moment. Sorry I forgot to mention my first job today is to get the manifold skimmed!

Click to expand...

To clarify, what normally snaps the studs is the action of trying to undo the nuts. If the nuts are seized you may find that you apply enough torque that the stud snaps before the nut unscrews. Wurth studs are good replacements as the torque required to snap them is massive.

Click to expand...

Totally agree with all of this having been there. Really would leave well alone if one stays in. In fact now I've been there, I'd be tempted to use a nut splitter or summat to remove all existing nuts, rather than try to get them off! Certainly I wouldn't just have at em with a socket and bar!
Dead right about leaving the studs in! and once skimmed enlarge the holes at both ends and then the next ones in, by a slightly lesser amount, to make fitting easier and warping harder to cause further problems, although usually once a warped manif has been skimmed they usually stay put.

Well had the manifold skimmed and fitted, keeping the existing studs and used the worth washers and bolts and the very last one pulled! Gutted! It's back off and between days graft 100miles from home I'll get someone to pick me up a bigger stud nut and appropriate tap! 1 day till I need it to tow the family caravan...

robhtid said:

Well had the manifold skimmed and fitted, keeping the existing studs and used the worth washers and bolts and the very last one pulled! Gutted! It's back off and between days graft 100miles from home I'll get someone to pick me up a bigger stud nut and appropriate tap! 1 day till I need it to tow the family caravan...

Click to expand...

Could be worse, there are many on here, me included, who have had to drill out studs broken off below the surface of the head.
Best of luck with it all, and don't forget to drill the hole bigger!

Stanleysteamer said:

Could be worse, there are many on here, me included, who have had to drill out studs broken off below the surface of the head.
Best of luck with it all, and don't forget to drill the hole bigger!

Click to expand...

Meant the whole in the manif, if it ain't obvs!

robhtid said:

Well had the manifold skimmed and fitted, keeping the existing studs and used the worth washers and bolts and the very last one pulled! Gutted! It's back off and between days graft 100miles from home I'll get someone to pick me up a bigger stud nut and appropriate tap! 1 day till I need it to tow the family caravan...

Click to expand...

I feel ya pain as I had to tap one (the last) hole to 10mm on my son's one. I already went armed from Hertfordshire to Herefordshire with my tap & die set 'just in case'. If you can use a starter, second & plug tap when you do it. Best of luck & enjoy that holiday.