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'93 940 Exhaust Manifold Gasket Replacement 900

Dear Fellow Brickboarders,

Hope you're well. I just reviewed FAQs prior to replacing failed exhaust manifold gasket (one failed, all will be replaced).

To ease nut removal, after several drenchings with PB Blaster, I wire-brushed the end of each stud, that protrudes past the nut. The reason: the exposed ends of the studs were heavily rusted, after 20 years (141K miles) of service. I used a Dremel and a stainless steel brush.

The stud threads, where covered by the nut, were in good shape - almost rust-free - as were the threads inside the nut.

Once the nuts "cracked free", wire-brushing the stud ends eased nut removal: the nuts did not have to push aside 20 years of corrosion on the exposed stud ends. Easing nut removal cut the risk of shearing a stud.

I will not re-use the nuts and will coat the stud threads with nickel anti-seize.

I appreciate having handy the concentrated "how to" wisdom in the FAQs!!

Hope this helps.

Yours faithfully,

Spook








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    '93 940 Exhaust Manifold Gasket Replacement 900

    Your's and Phil's remarks just entered the FAQ. Gracias!
    Steve
    --
    See the 700/900 "FAQ" at the menu bar top screen left side.








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      '93 940 Exhaust Manifold Gasket Replacement 900

      Dear Steve,

      Hope you're well. Job 98% done (I await from Volvo, three more manifold nuts)..

      The manifold nuts are shiny black, not copper-colored. I used a small jack to support the exhaust system, once I removed the two, 18mm bolts, that secure the system bracket to the transmission housing.

      I used a screw-driver to separate the manifold from the head. To avoid damaging the head's manifold sealing surfaces, I inserted the tip to the screwdriver at the top end of the gasket, near the stud. With the jack supporting the exhaust system, it did not take much prying to free the manifold from the head.

      I used a 320-grit sandpaper to clean the manifold surfaces of gasket debris, etc.

      All-in-all, the job went smoothly: no studs snapped, thread corrosion was minimal, and exhaust bracket bolts came out easily.

      Once I get remaining manifold nuts, I'll torque to spec: 25 newtonMeters = 18 pound/feet.

      Hope this helps.

      Yours faithfully,

      Spook








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      '93 940 Exhaust Manifold Gasket Replacement 900

      Muy Estimado Don Esteban,

      Hope you're well. The beeswax option is in the FAQs. I did not see any guidance as to cleaning the stud ends, to ease nut removal. The nuts are lock-nuts, so fit the stud very tightly. Removing the corrosion at the stud ends will ease the flow of beeswax or PB Blaster (or other penetrating oil).

      Hope this helps.

      Yours faithfully,

      Spook








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    '93 940 Exhaust Manifold Gasket Replacement 900

    Hi Spook-

    Thanks for the update. I've started using beeswax to loosen rusty nuts/threads. Heat up the stud with a torch, then press a chunk of beeswax on the end of the stud. Capillary action draws the melted wax into the thread ands makes removal a breeze. I get the chunks of beeswax off ebay for very low prices. This keeps my wife happy because I'm not ruining her decorator candles!

    All the best

    Phil C







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