FENCE1775 Posted November 5, 2011 Share Posted November 5, 2011 STAINLESS STEEL STUDS ARE SNAPPING OFF , DEALER DID JOB IN 2007NEW STUDS ARE NOT STAINLESS BUT CAN'T GET ALL THE OLD ONES OUTHAVE 2 I'M DRILLING WITH CARBIDE BITS " ANY TIPS WOULD HELP" TORQUE SPECS ALSO Quote Link to comment https://www.bigmacktrucks.com/topic/21444-exhaust-studs-breaking-on-2005-ac-460p/ Share on other sites More sharing options...
Bollweevil Posted November 5, 2011 Share Posted November 5, 2011 If you have studs broken off flush, or slightly protruding, lay a thick washer, with a smaller inside diameter over the broken stud, and mig weld the washer to the stud. Get enough weld on it to put some heat into the stud. Then weld a nut to the washer. Using a combination wrench , loosen gently at first, or loosen and tighten until it will move. If the weld breaks, do it again. You will have a better success rate than trying to hand drill a hardened stud while staying free of the threads. Even thinking about broken easy outs makes my head hurt. 1 Quote Link to comment https://www.bigmacktrucks.com/topic/21444-exhaust-studs-breaking-on-2005-ac-460p/#findComment-90026 Share on other sites More sharing options...
rhasler Posted November 5, 2011 Share Posted November 5, 2011 Are you going to install the multi layer steel exhaust manifold gaskets with the spacers over the studs? Quote "Mebbe I'm too ugly and stupid to give up!" Link to comment https://www.bigmacktrucks.com/topic/21444-exhaust-studs-breaking-on-2005-ac-460p/#findComment-90030 Share on other sites More sharing options...
shortstack Posted November 5, 2011 Share Posted November 5, 2011 I did that a few months ago. I wouldn't even try drilling them out. Do like Bollweevil said and weld a nut to them. Trey Quote Link to comment https://www.bigmacktrucks.com/topic/21444-exhaust-studs-breaking-on-2005-ac-460p/#findComment-90033 Share on other sites More sharing options...
RowdyRebel Posted November 5, 2011 Share Posted November 5, 2011 I have the external style easy outs for use on any bolts that snap leaving enough protruding for these things to grab onto. I've always hated the internal ones that require drilling....never thought about welding a washer & nut to the broken bolt.....EXCELLENT idea!Hell, even the act of welding the washer & nut to the bolt will heat up the bolt and might break it free...Come to think of it, I did weld a bolt onto a plug after stripping the dang hole out trying to remove it from the F250's rear axle....resealed the rear diff cover and then couldn't get the stupid plug out to add the gear oil! I was about to drill & use an easy out, but was reluctant because I had JUST resealed the cover...and would have to remove it to ensure there weren't any metal shavings inside. That's when I saw my welder sitting in the corner of the garage.I prefer the plugs with the external square that you can put a wrench on rather than these stupid ones that have the internal square drive.... Quote When approaching a 4-way stop, the vehicle with the biggest tires has the right of way! Link to comment https://www.bigmacktrucks.com/topic/21444-exhaust-studs-breaking-on-2005-ac-460p/#findComment-90039 Share on other sites More sharing options...
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