Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

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alpenweiss2
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Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by alpenweiss2 » Wed Jul 11, 2018 5:52 pm

We live in deepest rural France so most of the time I have to resort to fixing issues on the car myself! We have had some running issues on our 1999 1.9tdi Wagon and I thought the turbo may be gunked up again so decided this afternoon to do the Mr Muscle treatment for the second time.

The car has had the EGR valve removed for a long time with just a blanking plate on the exhaust manifold and the alloy manifold.

Unfortunately when trying to undo one of the nuts holding the blanking plate onto the exhaust manifold I snapped the stud!! Quel catastrophe!!

I didn't use much force on the socket but there you go...it just sheared the stud. The manifold is now blowing quite badly and the outcome is that the car is running in limp mode!!

Being in rural France it is difficult to know what to do?

A French friend who is quite knowledgeable about cars suggested a permanent fix would be to cold weld around the blanking plate and broken stud to seal the gap where the gasses are escaping? I am a bit worried about this because the French CT (MOT equivalent) is becoming very strict and the car may fail on having being modified. I have the original EGR valve to refit it if I can get the broken stud out and also remove the nut on the other stud?

Any thoughts people. Feeling a bit desperate!

Jultsu
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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by Jultsu » Wed Jul 11, 2018 7:01 pm

Maybe you could try drilling and tapping a hole in the manifold? A new (used) manifold wouldn't probably cost much and they are a fairly common item.

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BIG F@ TW@
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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by BIG F@ TW@ » Wed Jul 11, 2018 7:57 pm

Could you cobble something together using a hose clamp or two? Clamping over the delete blank.

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Jultsu
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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by Jultsu » Thu Jul 12, 2018 6:43 am

Shouldn't be more than a days work to remove the intake and exhaust manifolds, swap the broken one to a new one, throw in new gaskets and clean the intake ports from gunk.

alpenweiss2
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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by alpenweiss2 » Thu Jul 12, 2018 6:57 am

Jultsu wrote:
Thu Jul 12, 2018 6:43 am
Shouldn't be more than a days work to remove the intake and exhaust manifolds, swap the broken one to a new one, throw in new gaskets and clean the intake ports from gunk.
I wouldn't feel confident to do this work myself and would cost a fortune for a garage here in France to do it!!

Jultsu
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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by Jultsu » Thu Jul 12, 2018 12:35 pm

Pics from the current situation would be great. The other one snapped clean off or left a small base on the port?

alpenweiss2
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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by alpenweiss2 » Thu Jul 12, 2018 1:51 pm

I will try and post a photo. If I can get the other nut undone without breaking the other stud and then lift off the blanking plate there will be about 3mm of the broken stud above the port. I have a friend locally who has a stud removing tool. Would it be best to heat it with a gas gun? What size thread is the stud and what length? Is it M8 x 46mm? What are the chances of success?

Jultsu
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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by Jultsu » Thu Jul 12, 2018 6:17 pm

If you don't want to remove the manifold, I'd try to grind the stub flat and drill maybe a 5mm hole through the old bolt and make a 6mm thread inside of it.

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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by passat-pd130 » Tue Jul 17, 2018 2:24 pm

Jultsu wrote:
Thu Jul 12, 2018 6:17 pm
If you don't want to remove the manifold, I'd try to grind the stub flat and drill maybe a 5mm hole through the old bolt and make a 6mm thread inside of it.
the problem with that is during the years of heat and cooling cycles they can become very hard to drill

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Re: Urgent, Urgent, Urgent! Snapped stud on exhaust manifold.

Post by Jultsu » Tue Jul 17, 2018 4:07 pm

I agree, it probably will be difficult, but a new hard drill bit combined with slow speed and constant feed of some cutting fluid (water will do fine) will do the trick.

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