I was wondering if anyone has drilled out broke off exhaust studs with the engine in the car? I have IIRC 2 broke studs on the passenger side which creates a horrible exhaust leak that will drive me crazy if I don't deal with it soon. Any thoughts or ideas on this?

 

Hi Jason,
Yes this can be done - did it myself last month. If it is only the rear most stud you will be ok - any of the others will be difficult to get to though. You need to remove the complete exhaust system and the heat shields.
Space is very tight and the only tool I found that would fit was a small air powered right angled die grinder. I had to shorten a drill bit to fit the space also.
Make sure you have good eye protection as you will get covered in metal chips if you have to do the job on your back under the car as I did!! Took me about two days to complete the job and not one I would want to do again.

 

I'm afraid that when I pull the exhaust the other bolts may break as well. Did any of your other bolts break during the process?

 

I'm also afraid of drilling a bit off the mark and ruining the block.

 

try taking it to somone with a mig welder and have them weld a nut on the broken stud usually the heat of welding loosens the stud and the nut lets you back it out

 

I'd try it but it's broke flush no nub left.

 

I did this. Needed a right-angle drill adapter and cut-down drill bits. Then I broke off the easy-out and that's when the fun really started.

I suggest rolling this into other projects that require pulling the engine. Otherwise get some left-hand drill bits and maybe you'll get lucky.

 

Wont matter, a good welder can weld a nut on it and get it out, as long as there is room to do it.

No way would I try to drill it in the car.

 

Whatever you do, don't use easy-outs. Those things snap off on a regular basis (ask anyone that has used one) and they are hardened steel, so a bitch to get out once its snapped off.

They should be banned by the UN...

Good luck.

 

even if the stud is broken below the surface a good welder can fill it up till there is enough to get a nut welded on thats the safest route to try first

 

No other studs broke when removing the manifolds - it seems it is the rear most ones that are most prone to breaking and you just have to be very careful to maintain the correct angle on the drill to make sure you don't damage the block.
I would suggest the welding option as a first choice however.

 

Yep it is the standard rear passengerside studs that are broke. I think two of them. As far as easyouts they should be banned. I used one and it broke during my spring and shock job. It delay my job by a month or more trying to figure how to get it out. Ended up using several tungsten carbide drill bits to do it. Then I had to oversize the hole and install a threaded insert. I WILL NEVER USE AN EASY OUT EVER AGAIN ON LARGE BOLTS