ka24e exhaust manifold stud problem (broken off in block)

[rocksteady_racer]

Ok I got this ka24e I'm pulling out of my 90 240 for a rebuild and turbo install. Anyway the spark plug hole needs to be retapped, and before this one of the fuel rail bolts broke off in the block so I had to drill it out and retap it larger. One of my exhaust manifold studs broke off in the block (while it was driving one day not when I was removing lol). I don't want to end up having to retap the hole larger with a stud. Any tricks with getting it out without making the hole bigger? Or if it does get to big do they sell some sort of threaded reducer to put in an enlarged thread to reduce the size back to stock? The studs torque is too great to remove with a stripped/broken bolt remover right? Any suggestions would be greatly appreciated. Thanks in advance. The engine's compression is perfect so I don't really want to get a different block.

[s13silvia123]

PB blaster is your best friend when taking bolts off. all you have to do is spray that stuff on the night before or 15-20 minutes before any work and you'll have an easier job

[Steve Lloyd]

the manifold bolts to the head, not the block, so if you already have a screwed up spark plug hole, and now a broken exhaust stud, you should just buy a new head since you are rebuilding anyway.

A bolt extractor kit from Sears will work wonders as well, the manifold bolts aren't torqued in there very tight at all, most of mine came right out since the nuts were corroded to the studs. Just soak it in PB blaster, then use the bolt extractor to remove it.

[rocksteady_racer]

Ah. I didn't realize with the sohc head that the spark plug threads were in it too. I knew that that with my ka24de and sr20det that their in the head. Duh lol. Good point that prob make my job ten times easier. Thanks

[rocksteady_racer]

Ah. I didn't realize with the sohc head that the spark plug threads were in it too. I knew that with my ka24de and sr20det that they're in the head. Duh lol. Good point that prob make my job ten times easier. Thanks

[Cyprian]

Left hand drill bit, if you have no other option.

[stinky_180]

other options is using a mig welder and welding a washer/nut on the stud. much easier then using those 'easy outs'

[VG30Drift]

the manifold bolts to the head, not the block, so if you already have a screwed up spark plug hole, and now a broken exhaust stud, you should just buy a new head since you are rebuilding anyway.

A bolt extractor kit from Sears will work wonders as well, the manifold bolts aren't torqued in there very tight at all, most of mine came right out since the nuts were corroded to the studs. Just soak it in PB blaster, then use the bolt extractor to remove it.

This worked for me. I used a left hand drill bit to drill the hole for the bolt extractor, and some of the broken studs came out just from that. They aren't torqued that tight.

[rocksteady_racer]

O cool I never even heard of left hand drill bits - sounds sweet I'll try that:)

[KingKong8247]

Or use some vice grips. What I like to do is heat up the bolt, shock it with PB blaster or ice which in theory will break lose the rust (that is holding the bolt in place) from the bolt expanding and contracting. Do that a few times and it should come out very easily.


Or if it does get to big do they sell some sort of threaded reducer to put in an enlarged thread to reduce the size back to stock?

If you have to drill it out just use helicoil to get the thread back to stock size.
This is how I fixed my valve cover.
http://zilvia.net/f/tech-talk/184013-how-use-helicoil.html