removing broken exhaust manifold stud w/ broken extractor - Zilvia.net Forums | Nissan 240SX (Silvia) and Z (Fairlady) Car Forum

240sxvaj · 01-02-2008, 05:43 PM

like the topics says i have one broken stud while i was replaceing my turbo manifold.

so drill a whole with a small drill bit and i use the extractor.
some how the extractor broke off.
now im in some serious Shlt
the extractor is titanium and when i tried to redrill a hole it doesnt seem to cut through. Do anybody know if titanium is drillable?
anyone had this problem before?

unicoladron · 01-02-2008, 05:57 PM

hmm now you might want to try to extract the broken stud with vice grips. also get yourself a torch and heat up the stud too and have a friend try to coax it out, maybe this will help you remove the broken extractor.

Irukandji · 01-02-2008, 05:59 PM

Exact samething happened to me. I said fuck it, and made sure all the other studs were tight. I had no leaks on between the head and turbo manifold.

240sxvaj · 01-02-2008, 06:00 PM

a torch? i'll give that a try

anyone had a similar problem?

i dont want to leave that broken stud in my engine when replaceing the new stud.

i just dont feel safe with 7 studs holding my manifold

WERDdabuilder · 01-02-2008, 06:35 PM

happened to me a year ago.

one of the studs on the header(KA) broke and was stuck in the engine. went and got a tap/extractor or whatever from sears and started to drill. came out with no problems.

gluck with you problem

yarou · 01-02-2008, 06:43 PM

you could weld on a piece of metal to whatever's left of the broken stud and unscrew the stud out along with that broken off titanium thing.

DisEpyon · 01-02-2008, 07:46 PM

dam that sux man, same sheit happend to me, few days ago.

I had to take off my oil pan to weld a fitting onto it, while unbolting it, one of the bolts snaped on me, the bolt head snaped/broke off. It snaped flush on the upper oil pan flange. so i tryed the same thing you did. I first tryed to drill out the stud, but i could not get it to start a hole. so what i did was try welding(i used a tig welder) a bolt onto it, or weld on a washer, then a nut onto the washer. it worked for a short time, then the bolt/stud broke off again, but this time even further down in the hole, so then i tryed the extractor method again and this time i got a hole started, but when i used the extractor it broke off just like you stated, from there, i gave up, and just bolted up the 9 out of 10 bolts on. luckly its not leaking yet. I figure if i have to take out my motor for some reason, ill retry and get the broken bolt out of there. kind of hard working on it upside down underneath the car.

but i suggest the welding method, i did research on it and alot of people had success. I think in your case it will be easier since your not welding underneath the car and you can actually see what your doing. that is if you have access to a tig welder, i wouldnt try a mig or a stick welder, to messy and big, not precise enough.

jspaeth · 01-02-2008, 10:14 PM

I've never tried it before, but I would think if you torched the whole area, it would cause the metal to swell, then quickly cool just the stud, and hopefully it will shrink up faster than the hole it's in

240sxvaj · 01-02-2008, 11:50 PM

i will try the welding.

thanks to you all!

01-02-2008, 05:43 PM	#1
240sxvaj Nissanaholic! Join Date: Dec 2007 Location: So-Cal! Age: 31 Posts: 2,192 Trader Rating: (38) Feedback Score: 38 reviews	removing broken exhaust manifold stud w/ broken extractor like the topics says i have one broken stud while i was replaceing my turbo manifold. so drill a whole with a small drill bit and i use the extractor. some how the extractor broke off. now im in some serious Shlt the extractor is titanium and when i tried to redrill a hole it doesnt seem to cut through. Do anybody know if titanium is drillable? anyone had this problem before?

01-02-2008, 05:57 PM	#2
unicoladron Zilvia Junkie Join Date: Jul 2007 Location: Long Island, NY Age: 37 Posts: 568 Trader Rating: (0) Feedback Score: 0 reviews	hmm now you might want to try to extract the broken stud with vice grips. also get yourself a torch and heat up the stud too and have a friend try to coax it out, maybe this will help you remove the broken extractor. __________________ 1993 KA24DE for sale with 180k..running when pulled.... need to get rid of ASAP...i'm moving

01-02-2008, 06:43 PM	#6
yarou Zilvia Addict Join Date: Sep 2006 Location: Bay Area, CA Posts: 661 Trader Rating: (8) Feedback Score: 8 reviews	you could weld on a piece of metal to whatever's left of the broken stud and unscrew the stud out along with that broken off titanium thing. __________________ jumbosandbox.blogspot.com

01-02-2008, 10:14 PM	#8
jspaeth Nissanaholic! Join Date: Mar 2006 Location: Philadelphia suburbs Age: 37 Posts: 2,347 Trader Rating: (7) Rides Gallery: jspaeth Feedback Score: 7 reviews	I've never tried it before, but I would think if you torched the whole area, it would cause the metal to swell, then quickly cool just the stud, and hopefully it will shrink up faster than the hole it's in __________________ Daily driven

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01-02-2008, 05:59 PM	#3
Irukandji Post Whore! Join Date: Jul 2004 Location: Compton Posts: 4,268 Trader Rating: (0) Feedback Score: 0 reviews	Exact samething happened to me. I said fuck it, and made sure all the other studs were tight. I had no leaks on between the head and turbo manifold.

01-02-2008, 06:00 PM	#4
240sxvaj Nissanaholic! Join Date: Dec 2007 Location: So-Cal! Age: 31 Posts: 2,192 Trader Rating: (38) Feedback Score: 38 reviews	a torch? i'll give that a try anyone had a similar problem? i dont want to leave that broken stud in my engine when replaceing the new stud. i just dont feel safe with 7 studs holding my manifold

01-02-2008, 07:46 PM	#7
DisEpyon Zilvia Junkie Join Date: Jun 2005 Location: ? Posts: 574 Trader Rating: (0) Feedback Score: 0 reviews	dam that sux man, same sheit happend to me, few days ago. I had to take off my oil pan to weld a fitting onto it, while unbolting it, one of the bolts snaped on me, the bolt head snaped/broke off. It snaped flush on the upper oil pan flange. so i tryed the same thing you did. I first tryed to drill out the stud, but i could not get it to start a hole. so what i did was try welding(i used a tig welder) a bolt onto it, or weld on a washer, then a nut onto the washer. it worked for a short time, then the bolt/stud broke off again, but this time even further down in the hole, so then i tryed the extractor method again and this time i got a hole started, but when i used the extractor it broke off just like you stated, from there, i gave up, and just bolted up the 9 out of 10 bolts on. luckly its not leaking yet. I figure if i have to take out my motor for some reason, ill retry and get the broken bolt out of there. kind of hard working on it upside down underneath the car. but i suggest the welding method, i did research on it and alot of people had success. I think in your case it will be easier since your not welding underneath the car and you can actually see what your doing. that is if you have access to a tig welder, i wouldnt try a mig or a stick welder, to messy and big, not precise enough.

01-02-2008, 11:50 PM	#9
240sxvaj Nissanaholic! Join Date: Dec 2007 Location: So-Cal! Age: 31 Posts: 2,192 Trader Rating: (38) Feedback Score: 38 reviews	i will try the welding. thanks to you all!