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Broken exhaust stud removal

Discussion in 'XJ Technical Chat' started by splazoid, Feb 25, 2012.

  1. splazoid

    splazoid Member

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    Howdy all. I broke the tip off an exhaust stud and need to remove it. There is still about an inch and a half sticking out of the head, and I've had it soaking in kroil for 3 full days now. I've read that I should heat the head before unscrewing it. One question, clockwise or counter clockwise? And what's the best tool to grab on to it with, vice grips? Should I replace them all while I'm here, or just the damaged one?
     
  2. boostenlebaron

    boostenlebaron Member

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    Id try to rethread the part showing and use 2 nuts to undo it. Apply heat to the head as well.
     
  3. RickCoMatic

    RickCoMatic Well-Known Member

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    If there's enough Threads; the "2-Nut" -or- "Nut-Washer-Nut" technique is effective.
    Thread 2 Nuts on the Stud.
    Tighten the 2 Nuts -- together.
    Hold the outside Nut.
    Try to Undo the Inside Nut.
    You UNDO the Stud by turning it to the LEFT ::: Counter-clockwise.

    IF you can extract those Original Fastener, ... REPLACE them all.
    CHASE the Threads with a Tap.
    TREAT the Threads with Anti-Seize Compound.

    ::: TIP :::

    Impact is sometimes effective loosening the Studs.
    You can apply some Impact to the Stud using the 2 Nut Method.
    Put the BOX End of the Wrench over the Stud.
    Thread Nut 1.
    (Washer; optional)
    Thread Nut 2.
    With 2nd Wrench ... tighten the 2 Nuts together.
    HOLD the outside Wrench.
    Strike the Inside Wrench.
    ::: If there is no room to swing a Mallet or Hammer ... Place the End of a Hard Wood Hammer-handle to the Inside Wrench and Strike the Opposite end of the Hammer Handle. :::
     
  4. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Counter-clockwise and if you can get a good enough grip with vice-grips it should unscrew rather easily. Heating the head wouldn't hurt but probably won't be necessary. The bolt holes on the 550 head don't go all the way through, so it's not rusted from behind. It broke because the nut was rusted to the stud which is why you have a nice long stub.

    Replace it with another stud, not a bolt. And use anti-sieze as Rick suggested.
     
  5. splazoid

    splazoid Member

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    This worked perfectly! Thankfully the kroil got in there much nicer after 3 more days of sitting. A couple of wrenches on it, and it spun right out. Im so glad there was just a bit of threaded end on there, or this would have been a whole different story.
     

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