Today I'm putting this thing back together. It's cold and windy out, but not snowing yet. Anyway, the urgency of the situation is really there.

I'm talking about the connection between the exhaust manifold to the downpipe. Non-turbo. When I took it apart a month ago, there were two studs in the manifold and one bolt holding the manifold and downpipe together. I wanted to be original so I got another stud fromthe dealer. Was like $8, and that was the wholesale price. THen bought 3 stover lock nuts from nut and bolt place because new volvo nuts were $30 for all three. Have new Volvo gasket too.

Problem is now that all the studs are too short! There's like 2 threads exposed after mating the downpipe flange and I can't get the nuts threaded. I can't believe this is happening. Makes no sense, because how did it hold together before? And I can't loosen the studs out of the manifold either. If I could, I will just get some new bolts from home depot and use lockwashers to keep them from backing out.

Guys, this is an emergency.

Got the last stud out just now. During the course of a typical day at work, I meet and deal with a variety of machine shop guys, mechanics and machinists. I mentioned this problem to a few different guys today, and they all had elaborate (but not necessarily wrong) solutions, along with offers to do it. I was sort of leery all day though. But just now this guy said "I'll get it out" and even though I was apprehensive I showed it to him. He took out a pipe wrench and reefed on the stud. Sure enough, it came out.

This is the best thing that has happened to me in a long time. Ok maybe not.

Unfortunately, the local nut and bolt place doesn't have the correct studs. The originals are 40mm long, and you need 50mm - 55mm I figure. The dealer sells these 40mm long ones. I just don't understand why. I did go buy bolts, but it would be so much nicer for installation to use studs when you're trying to put this thing back together. I will try NAPA and if they don't have studs I'll just put the bolts in.

Can you get some Visegrips on it and squeeze the flanges together?

Wrong studs: get longer ones. I've done the Stalingrad routine out lying in the snow and wind and my sympathies go out to you. For tips on old stud removal, take a look at the FAQ sections:

http://www.brickboard.com/FAQ/700-900/Exhaust.htm#Exhaust_Manifold_Gasket_and_Studs_Replacement

http://www.brickboard.com/FAQ/700-900/MechanicalTips.htm#LooseningTightBolts

--
See the 700/900 FAQ at the select shortcut button on the top right of the screen.

Can you get some Visegrips on it and squeeze the flanges together?
Well I have the manifold off right now, sitting on the bench.

@ Steve: Ya it's really bad when you're trying to do things in the freezing cold. Not the first time for me either. I'll try those other tips today.

What were you using for heating the manifold? You'll need oxy/acetylene to get it hot enough fast enough--if it you heat it too slowly the stud will expand along with the cast iron and keep it locked in--maybe you need to take it to a repair shop now that the manifold is off. You can get it cherry red and it'll be ok.

Was just using my propane torch. I didn't get it cherry red.

On the plus side, I did get one of the two studs out when my neighbour was walking by and I explained the problem. We used the double nut method wiht a secondary wrench to hold the outside nut. He got one out that way. I guess I wasn't trying hard enough. But on the last one it wouldn't work because the threads are way too chewed up. The nuts would just spin on the stud. May have to take it in for that last one.

When you install the new studs, use nickel-based high temperature antiseize to make sure this problem does not recur. And make sure the threads are OK so they don't loosen.
--
See the 700/900 FAQ at the select shortcut button on the top right of the screen.

I will. But I won't be using Volvo studs. They are too short. What a pain in the ass. I"m going to go get some studs from the local nut and bolt place. Failing that, I'll just use the 50mm long bolts I picked up today instead. Now I just have to find a machine shop that can take this last one out.

Well heating it didn't do anything. Maybe I wasnt aggressive enough with the torch. But I didn't want to risk cracknig the manifold.

I feel like I'm going to cry, I don't know what to do now. I could probably get by by only putting the new stud in a few turns, to get extra length to put the nut on. And I can get a couple threads on one of the other studs. But on the last one there's only 1 thread available and I can't get anything on it. I can't believe this is happening. If I could just get those studs out, I can put bolts in. I already know the size: M10x1.5, 45mm long.

just get longer bolts... volvo has given me the wrong bits afew times. you can go to any jobber for the bolts, buy long and cut to length if you need to

That's what i'm going to do. Just have to get the studs out first. Using PBlaster now.

Yep, blaster and you may double nut it for removal.
--
Post Back. That's whats makes this forum work.

Tried double nutting, it won't work. Both nuts start backing off. Vice grips won't do it either. May have to heat the manifold threaded area and try that.

Is it the same downpipe? Old gasket stuck on manifold? Downpipe stuck against support bracket? New gasket way to thick? You could use a jack under the pipe for a helping hand.I wish you less wind and more warmth for your next attempt.

Bill

Thanks for the input, but it's the same pipe, old gasket is out and surfaces are clean, support bracket wasn't in the way, new gasket looks the same as the old one and it's a volvo part. Today it's supposed to be nicer. Yesterday the wind was going at 84 km/h.