I had the pipe immediately downstream from the exhaust manifold on a 245 1986 changed at a muffler shop in June 2000. This spring I noticed that there was a leak where that new pipe joins with the manifold; the gasket was burnt and it was changed on the warranty. Since then the gasket has been changed twice already and a stud was broken by the mechanic when the gasket was changed for the second time.

About a month ago the stud was changed and two gaskets were put in by the same shop . The people there suggested that the stud was getting loose because of irregular idle.I think the stud is gettin loose because in removing the broken stud in the manifold, the female threads were enlarged or damaged. I wondered why it would get loose since none of the other studs that are connected to the engine or the manifold have gotten loose.

This weekend as I was puttering under the hood, I started the engine and put my bare hand very close to the gasket and I felt that there was still a leak at the same place. I am about to return to that shop for the fourth time in less than six months and would like someones opinion on a better cure than changing the gasket and the stud again.

Is there something that can be done to keep that stud in there such as putting some special glue or cement in the manifold hole (where the stud goes) that would withstand the heat or putting an oversize stud . Can a clamp be put externally to keep everythig tight. Apart from the risk of carbon monoxyde poisoning the exhaust gases which probably corrosive and damp are being blown on the pipe going from the water pump to the heater and accelerating its corrosion