broken exhaust stud - Dodge Dakota Forum

Subject: broken exhaust stud
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My 2003 SXT has two broken exhaust manifold studs/bolts. They are the front two on the passenger side. At first I thought that I had a lifter noise on that side.

Looks like there is enough of room to get to them if the inner wheel well is removed. How hard is it to drill those guys out?

Any suggestions on the best removal tools will be appreciated.

Thanks in advance!

dakota49
Gen I

10/08/2008
21:08:02

RE: broken exhaust stud
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It may be easier to remove the manifold then grab a hold of the stud (if there is any thing sticking out) And use some vice grips and unscrew, just soak with wd40, liquid wrench, or some other pinatrating oil the remove. Before you try to remove the manifold soak the rest of the bolts/studs with the afore mentioned oil(s) and work slowly to remove. I have drilled before, but its hard to do with the engine/head still in the truck. If they broke off square that's great, I've never been that fortunate myself, its always broke off at an angle, the problem is when you try to drill, the drill tries tomove away from the center and winds up hitting the manifold and making things worst.
It can be done if you are careful.
Good Luck
Dakota49

dakota49

harry from ct
Dodge Dakota
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10/08/2008
22:25:07

RE: broken exhaust stud
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http://www.tvproducts4less.com/pro-grabit.html?c=1&kw=removing%20stripped%20screws <<<<copy paste...works every time
i used it 4 times.........

01DakSport
Dodge Dakota
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10/08/2008
22:46:37

RE: broken exhaust stud
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if you can get a torch, heat up the area around the stud red hot before you try to unscrew it. last time i tried that without heat, they ended up breaking off flush with the flange... not fun

jay
Dodge Dakota
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10/09/2008
06:39:01

RE: broken exhaust stud
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Thanks for the suggestions! I was planning on removing the manifold before I attempted this to see whats left. I have a bad feeling that they are broken off flush with the head.

GeoDak
Dodge Dakota
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10/09/2008
09:18:16

RE: broken exhaust stud
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One trick that works you can grind them flat to the head and center punch them ,then drill slowly starting small and going to bigger bits.

Hope it helps

jay
Dodge Dakota
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10/09/2008
20:09:44

RE: broken exhaust stud
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I'm planning diving into this project tomorrow after work. I'll let you guys know how it goes.

Thanks again!

J and J Auto
GenII

10/10/2008
01:49:10

RE: broken exhaust stud
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here is how I do it

If there is enough to grab with a quility pair of
vise grips that usualy works

If not

put manifold back on get a drill that just fits
into the hole and drill into stud 1/8 to get a
dead nuts center mark, now have someone stand back
and line you up and step drill starting with 1/8
drill, go to 1/4 than try a good easyout like the
snap on brand with a short bit in a socket

If not

get 2 left hand drills 1 smaller and 1 tap size
and dril out most times it will hook the left
hand drill and come out

Another method is you can weld something to the
stud than turn it out

I have run into this so many times instaling
headers a lot of the trucks came from the factory
with broken studs

Larry
J&J Auto

jay
Dodge Dakota
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10/10/2008
18:37:50

RE: broken exhaust stud
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Success!!!

Thanks to all for the great suggestions. One of the studs popped right out while I was drilling it with a reverse drill bit. The other was a bit stubborn. I used a new set of easy outs I bought at Harbor Freight for this job. Worked great.

dakota49
Gen I

10/10/2008
23:17:08

RE: broken exhaust stud
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Jay, glad to hear you got them out. Thanks for letting us know.
Good Luck
Dakota49

dakota49

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