I need some ideas on how to remove a stripped stud on the exhaust outlet. Who ever put the exhaust header on cross threaded the nut onto the stud. I was looking things over and decided to put on a new exhaust (short shots). I decided to change the studs due to their condition, nuts, retention rings.

Three of the studs came out with no problem by running two nuts together and then backing the inside nut out but, the one furthest on the front exhaust port won't budge and that is the one that was cross threaded. I basically have a useless stud sticking out of the motor/ exhaust port. I've tried PB blaster and that spray that freezes. The stud has no usable thread material on it. Tried vice grips and such.

Anybody have any ideas about what to do next??


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Find somebody that can weld and weld a nut to the stud, try again.

 

Just tried that. . .broke the stud off in the block. . .Dammit. I'm guessing I have to take it to a shop now so they can tear it down and take it to a machine shop

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I'd take a picture of it and show it to your most trusted mechanic. Auto or mc for fresh ideas.

If I could get a drill bit in there I'd start the ez out process. Sears has some new type ez outs. Spray a few squirts of penetrating oil in there let sit overnight and have at it.

I don't know if you have enough space to actually get in there straight but if you do try it when your fresh and not aggravated. Last resort pop the head and work it on a bench.

 

Local MC shop said it would be like 1100 to fix. . Local HD shop said would have to replace it for around 1500. . . F*** Me

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There is a bit available called a Rescue Bit that is a monster for drilling/reaming/cutting bolts check it online they have videos.

The trick is getting a hole drilled thru the exact center of that stud first. Heat would have been the first thing before busting it clear off 20-20 hind sight.

I have my doubts you can do that in the frame so probably need to pull that head and bench it to do it right. hth

 

Had heat on the head. . just corroded

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Yeah I been there too on cars and trucks, I feel for ya good luck!

 

Pull the head, get the correct size Monster bit that Car Doc made reference to, order the exhaust stud drill jig ($66.50) from Georges garage and drill it out. Or, jump on ebay and buy a used set of heads for $150, new head gasket, bolt on and go.

When you pull the head, take care to remove it without disturbing the cylinder to case seal at the base o-ring. Get a couple of 1/2" PVC couplings and use the short head bolts to secure the cylinder to the case while you sort out the problem. That way, you won't have to remove the cylinder to replace the base o-ring.

A PITA but not difficult. I can understand the machine shop charging out the wazoo for a one off job, set up time, etc.; however, the dealer probably has several stock take off heads laying around that they could give you and generate some good will instead of trying to take advantage; worst case, take $50 for the used head. Tell them to ki$$ your a$$.

 

That's crazy. Check some of the better motorcycle or machine shops in your area. A good shop should be able to drill and extract the stud without removing the head. They just need enough clearance to get on the stud squarely.