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Re: Arrgh! Turbo housing studs broken![200/84] posted by Doug on
Saturday, 27 February 1999, at 11:51 p.m.
No easy way out here. I had the same problem. On the way back from Florida to the frozen north (minnesota) my exhaust got louder and louder. I had one of the 5 studs holding the exhaust on and likewise no bracket, presumably removed by previous somebodies, and then there were none. So bailing wire had to do for hundreds of miles.
The problem with trying to drill them out on the car is that even with a close quarter drill / Milwaukee-Sioux it is hard to drill in the center of the broken stud due to not being able to see or hold the drill accurately. I have just relearned these lessons first hand. I have broken exhaust studs in both of my 245ti's. I was able to drill out 3 broken studs and on the 4th one I broke a hardened easyout and now I will probaly have to pull the head.
If you remove the turbo unit you take the manifold off and the turbo comes with it. None of the work is difficult, but it is time consuming. Replace the exhaust manifold studs now as they are sure to break later. The only tricks are getting the turbo oil drain pipe back in with out chewing up the rubber ring that seals it to block. Hang the exhaust manifold on the new studs and from underneath place the tube in its hole in the block, move the manifold closer to head and loosely install the two bolt that attach it to turbo, making sure that the drain pipe is centered and tighten everything up. Oh yes it is best to remove the O2 sensor and install it after manifold is back on head as it is easy to break the wire as it is a bit of a Houdini act getting the manifold/turbo of the space provided.
Re: Arrgh! Turbo housing studs broken![200/84] posted by Paul S on
Sunday, 28 February 1999, at 8:23 a.m.
Nasty business. Been there, done that. I must suggest ex. mani./turbo removal (prob. no need to take the turbo off the manifold (once out) if you can manuever the assembly).
Don't start with a regular right hand drill bit and "easy outs"!!!
Use left hand drill bits!!!
"I broke a hardened easyout and now I will probaly have to pull the head."
Maybe not.
I, too had this happen. I was really depressed, despondent..I didn't want to take my head off. So then I got rational. What's harder than the "easy out"?,....DIAMOND, of course.
Moto-tool to the rescue (or mini-angle air die grinder) with diamond studded bits. Believe it or not they are not expensive anymore. Harbor Freight, Northern, etc have diamond sets for cheap.
Slap the diamond bit in and grind the "easyout" and the stud very carefully. Just imagine you are a dentist...you just want to grind where the stud is. I was very carefull, so I didn't even have to enlarge the hole or use a helical insert. I just cleaned the hole up with the appropriate drill bit (angle drill) and retapped the 8mmx1.25 hole and slapped a stud in.
Anyhow, when you put it back together, be sure to use high strength studs, and lots of good antisieze compound.
--Paul "El Pablini" Seminara