bankz5152

bankz5152

Well-Known Member
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
 
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
Click to expand...
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 said:
what nut splitter do you use, James?
Click to expand...
generally a sharp chisel and a decent ball peen though i do use this type
upload_2016-11-9_18-53-48.jpeg
 
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.
 
jamesmartin said:
generally a sharp chisel and a decent ball peen though i do use this type
View attachment 110423
Click to expand...

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.
 
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.
Click to expand...
2 m8 nuts locked together
 
Last edited:
Which ones did you order? for future reference.


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

Cheers
 
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.
Click to expand...
the nuts are flange nuts a splitter wont help, can you borrow a few long extensions to make one long one
 
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...)
 
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...)
Click to expand...
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
 
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.
 
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.
 
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.
 
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.
 
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?
 
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?
Click to expand...

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
 
You must log in or register to reply here.

Similar threads

Sputnik01
Series 3 Strange gearbox goings on.
Replies
8
Views
2K
Sputnik01
Sputnik01
bankz5152
Fitting a Hybrid Turbo, any tips?
2
Replies
34
Views
2K
flat
flat
rockjunky
defender TD5 tricky progress on my front axle overhaul
Replies
0
Views
973
rockjunky
rockjunky
C
Disco 1 300TDI gearbox change/swap R380/LT230
Replies
1
Views
2K
Gazbo
Gazbo
Irishrover
'02, TD4, Rear suspension full overhaul
Replies
4
Views
2K
Irishrover
Irishrover