Not the type I keep finding topics about...

I ran a thread chaser over the threads of the stud (outside threads) while it was still in the head. The chaser took the threads right off...

Whether or not I used the wrong tool, my problem is that I now have a stud in the head with no threads on it to tighten the manifold down with.

So there's just a bare metal thing sticking out of the head. I tried filing two flat edges onto it and using vice grips to turn it out of the head, but no luck. Just keeps stripping more metal off and won't turn.

How would you get this thing out of the head? Almost every one of the bolts/studs has stripped the head holes, so I'm getting a helicoil kit today. But this one stud I can't do anything about, since it won't come out of the head.

So much fun!

My headgasket job was going along really smoothly until I tried to get the exhaust manifold back on...

 

try some heat and some penetrating lube, vice grips sounds like the best option. If you have a welder you can weld a nut to the end, that will give you good purchase and heat it up.

 

Ok thanks. Wasn't sure about the heat, since that should make things expand, not contract, right? Or will the heat make the aluminum expand faster than the steel bolt and make it loosen up?

Yeah...if it comes to it, I'll work with a welder.

 

Heat and vise grips will do the jobs. You know the old saying, "if you can eff it up with vise grips then it can't be effed up!"

But you are right, heat makes metal expand. The idea is that the metal expands and breaks the stud loose. Having the head and bolt made of two different metals does help since that both expand and contract at different rates.

Heli coils are a great fix option. I've used them plenty of times before with excellent results and longevity. Just make sure that you tap the hole deep enough and fully insert the heli coil so that you maximize your thread count and so that your heli coil isn't sticking out above the plane of the exhaust manifold surface.

 

If you go the weld a nut on route, be careful you don't get too much heat and warp the head. A couple other options are get an easy out or drill a hole in the stud and mash an Allen wrench in then turn it out. I had to do that on a Silverado I had. Actually went better than I thought it would. Good luck!

 

Thanks!

One of the helicoils I didn't do all that well and can't get it up to full torque, but the others are ok.

I'll take the manifold back off when the weather gets better and see if heating that stud will work.

 

So...

Definitely still louder than I'd like, so I have an exhaust leak.

One of the stripped bolt holes is the top back one, closest to the firewall. With the brake master cylinder right there, there is no way to get a drill in there to drill it out and helicoil it. (that i can think of)

I don't want to take the head back off...

Anyone have any experience repairing that hole with the head on?

 

I have used angle drills in tight spots and even cut bits down if I had to.

 

Is it accessible through the wheelwell? Not sure about your specific vehicle, but sometimes you can remove the inner fenderwell and see a new, easier route to it.

 

I don't think so...Pretty much blocked by the master cylinder.

Angle drill is a new thing for me though...I'll have to see what they're all about. My regular hand drill definitely will not fit for this hole.

Thanks!