After spraying PB'laster on the nuts holding the manifold and header pipe together and letting it sit a few days, one nut came right off... but the second one broke the stud. Third I didn't try.

Has anyone successfully drilled one of these out? Nothing to grab on to unfortunately.

Thanks,
-Ryan
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Athens, Ohio
1990 245 DL 130k M47, E-codes
1991 745 GL 280k (Girlfriend-mobile)
Buckeye Volvo Club

Actually, the stud is broken flush with the nut... which means the thickness of the exhaust flange is still on the stud. Is it a matter of torching and replacing?

Thanks!
-Ryan
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Athens, Ohio
1990 245 DL 130k M47, E-codes
1991 745 GL 280k (Girlfriend-mobile)
Buckeye Volvo Club

You torch it orange and it will come out easy. Oxy-acetylene being the weapon of choice, Mapp being a distant but acceptable second.
I just finished drilling a broken manifold stud out of my head.
May the force be with you......
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91 Brick turning 400,000 this month

I had an exhaust shop do the same thing. I ended up buying a helicoil kit from NAPA. I followed the instructions. Its been a year and its still holding tight.

Just get a set of nuts and studs from the dealership and have napa match the size for the kit for you.


Almost forgot get real good hardened drill bits to drill the hole for the helicoil. You can drill right where the broken stud is. I put the front pipe on first and stuck the drillbut through the hole. Make sure its straight.