I recently bought a 740T with a broken exhuast stud. Was making that loud annoying ticking noise and I decdied to try and fix it on my own.

THE EASY FIX:
I went to Home Depot and bought a Dremel. (the Dremel that has the long "hoselike" attachment) I went home and removed the exhuast manifold and turbo.
Hang the dremel on the hood and use a dremel drill bit on the end of the hose attachment and drill a holl in the stud. Then use the dremel engraving tool and slowly bore out the hole until you have cut away the entire stud.
Now that you have the hole and you've screwed up some of the tread simply retap the hole with new treats. (the taping tool cose me $29.00 at Canadian Tired) !!!!Important!!!! When tapping aluminum go very slowly in and out. 1/10th or a turn in and out seemed to do it. (aluminum is soft and tends to blister if you tap a hole to quickly)
After you tap the hole or holes insert new exhuast studs, attach the gasket and reassemble.
I'm proud to say my car runs like a dream and passed it's emission test the very next day. (not bad for a car that I bought for $1500) The entire job cost me $50.00 in parts and 6 hours of my time.
Next time your dealer tells you the head has to come off show them this message.


James Dichter
Toronto, Ontario, Canada
87 740 Turbo Stick.