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[Shelby]

Hi all,

I have just discovered (don't know how I missed this when I got the car, its not exactly hidden!) that the manifold probably needs replacing.  Now, that in itself may not be a major issue, however I believe that one of the bolts (nearest front of the car) has been broken off as it doesn't appear to have a nut on it and looks like it has had a bodge seal done on it.  The manifold is blowing / rattling slightly at that end.

I am assuming that its a steel bolt/stud and an aluminium head, so probably not an easy job to get it out (if possible)?

Any thoughts / ideas more than welcome on how to resolve this, am I pretty much definately looking at a new manifold and head?

Thanks

[RobG]

Quoted from "Sethsmate"

I made-up a sleeve that fitted snugly into the manifold flange.
This had a 1/8th" hole drilled centrally thro' it.
Fitted a 1/8th" drill bit into a right-angled drill, and drilled into the broken stud about 1/4"
Inserted an 'easy-out' and voila! - the broken stud unwound from the head.
Don't drill more than about 1/4" as you could drill into a water-jacket within the head.

[Abiton]

^^^ that should work, as long as the Easy-out doesn't break.

I made a drilling jig (with a hard 'cylinder bit' to centralise/keep-straight the drill)  that fitted over the most adjacent two good studs, then went straight in with a 6.8mm drill, then very carefully tapped it back to M8.  Needed a very small power drill to fit in the available space, but it worked.

Jig available for hire at very reasonable rates...

[Miggylover]

if you can see any of the stud pertruding, then  mig weld a bolt to it then just unbolt that.

[Shelby]

Thanks for the replies so far guys.  This is a significant job for me and I am a bit dubious about removing the manifold at the moment as I need the car on a daily basis for work.

As you can see from the pick, can't really tell in its present state how much, if any, of the stud is still sticking out from the head.



The rest of the exhaut is all fine, its just blowing / rattling slightly from that end of the manifold.

I don't have the money to replace any parts at the moment even if I wanted to, so it will have to wait until the end of April at the earliest.

[Abiton]

Sorry to add to your woes, but I think I can also see a crack in that manifold, near the middle, running out perpendicular to the engine's long axis, with smears of exhaust paste over most of it.

I think that's a very common cracking point, ours has one there, but it doesn't yet leak gas.

[Shelby]

Sorry to add to your woes, but I think I can also see a crack in that manifold, near the middle, running out perpendicular to the engine's long axis, with smears of exhaust paste over most of it.

I think that's a very common cracking point, ours has one there, but it doesn't yet leak gas.

Yea, am aware of that one and if I can get the stud out would probably look at replacing the manifold anyway.  Think they are around £100 from what I can find at the moment.

[Abiton]

Ah, I'm not sure my jig would be any good for your problem anyway.  When you said the stud nearest the front of the car, I assumed you meant the one on the bottom row, right next to the thermostat housing.
Looking at your pic, it's the front one of the top row you're on about.

FWIW here's my jig,  made for the 'front bottom' (  ) one.

[freecall666]

Thanks for the replies so far guys.  This is a significant job for me and I am a bit dubious about removing the manifold at the moment as I need the car on a daily basis for work.

As you can see from the pick, can't really tell in its present state how much, if any, of the stud is still sticking out from the head.



The rest of the exhaut is all fine, its just blowing / rattling slightly from that end of the manifold.

I don't have the money to replace any parts at the moment even if I wanted to, so it will have to wait until the end of April at the earliest.

mine was like that for years but it was the flex hose on the exhaust that was making all the noise when put your foot down big beeering noise came out, sounded like the manifold but was the flex pipe....

[Shelby]

Thanks for the replies so far guys.  This is a significant job for me and I am a bit dubious about removing the manifold at the moment as I need the car on a daily basis for work.

As you can see from the pick, can't really tell in its present state how much, if any, of the stud is still sticking out from the head.



The rest of the exhaut is all fine, its just blowing / rattling slightly from that end of the manifold.

I don't have the money to replace any parts at the moment even if I wanted to, so it will have to wait until the end of April at the earliest.

mine was like that for years but it was the flex hose on the exhaust that was making all the noise when put your foot down big beeering noise came out, sounded like the manifold but was the flex pipe....

Ill have a look at that aswell incase there is a problem there also, but as you can see from the pic, I need to get the manifold sorted anyway.