Volvo RWD Forum

INDEX FOR 1/2026(CURRENT) INDEX FOR 6/2008

[<<]  [>>]


 VIEW    REPLY TO THIS MESSAGE    PRINT   SAVE 

Broken exhaust stud delemma.

If the shop went and used an easy out, I'd doubt their ability to fix the situation.
I would find a machine shop and have them remove the bolt. The shop that caused the problem should pay for it, or get you a replacement head.

You have few options now. The head should be removed, and the bolt drilled out with a drill-press and cobalt steel bits. If they damage the threads, especially if they drill off-center, you're going to run into problems. If they can completely remove the stud, they might suggest a thread insert. In that case, she shop will need to check how thick an insert they can install. If there is too much material removed, you may need a new head.

There are a few shops that can do EDM. They essentially melt the steel by blasting it with electricity. The liquified steel of the bolt will splatter out and you can essentially drill with the electricity. The liquified steel won't bond permanently to the aluminum head, so it can be just brushed off. It also won't stick too much to the threads and can be cleaned out with a thread chaser.

Good Luck and kick some butt when you get to the shop. Or, let them be embarrassed by just acting dumbfounded that they would do something that unprofessional.

Happy Bricking... hopefully soon!
--
1990 740 Turbo, on its way to stock specs, maybe beyond






THREADED THREADED EXPANDED FLAT PRINT ALL
MESSAGES IN THIS THREAD

New Broken exhaust stud delemma.
posted by  Larue  on Thu Sep 16 14:58 CST 2010 >


<< < > >>



©Jarrod Stenberg 1997-2022. All material except where indicated.


All participants agree to these terms.

Brickboard.com is not affiliated with nor sponsored by AB Volvo, Volvo Car Corporation, Volvo Cars of North America, Inc. or Ford Motor Company. Brickboard.com is a Volvo owner/enthusiast site, similar to a club, and does not intend to pose as an official Volvo site. The official Volvo site can be found here.