exhaust manifold studs

[jeep90]

im having a little problem replacing the rear exhaust manifold stud on my 95 yj with the 2.5. i noticed that the rear one was broken off the other day and tried to drill it out. i have a hole about 1 inch deep into the bolt and tapped the easy out in with a hammer, but i can not get the stupid thing to turn. if i drill the whole out any bigger i will be hitting the threads on the one side because i couldnt drill the hole dead center on the bolt. what im thinking is drilling it out a little bigger and re-tapping it. after i get it re-tapped im going to use a grade 8 bolt instead of a stud. but i would rather get this out.

any thoughts?????

 

[newbie]

tapping the extractor in causes the bolt to xpand, try tapping and turning at the same time or try a left hand drill bit......... if that fails go with the retap and a grade 5 bolt long enough to thread a nut on and use as a stud without cutting off the hex head. you will find that the gr. 8 will break again due to it's higher carbon content making them less tolerant to expansion.

 

[jeep90]

very good point about the grade 8. im just trying to figure out what you meant about using a hex head bolt as a stud?

 

[bryanjeep]

I had to remove my head on my '94 2.5 YJ to get that darn stud out. Not easy doing it in the Jeep with the head still on there.

 

[west747]

you could have just taken the driver side fender off...makes it much easier to work on :lol: good point about the grade 8 bolt's

 

[jeep90]

hey snitty

i have it all drilled out waiting to get something to tap new threads. it really wasnt that hard, just a pain to get the drill where it needed to be.

 

[Bounty__Hunter]

I'd get the replacement studs from the stealership, they are now made better and are not prone to break.

I was lucky and the stealership fixed the front and rear studs for free on my '95 YJ, I was within the 8yr/80K extended warranty listed in the TSB for this problem.