fokker

Hi @ all
1999 4x4 XLT

I've found on Passenger Side, the aft lower Exhaust Manifold Stud is Broken,
and there is a slightly Exhaust leak. (i hear it, because i know it)

The Stud is NOT Flush with the Head, but flush with the Flange.

Today i tried to drill them out, but no chance.
first of all, its nearly impossible to reach the Stud with a drill bit.
i've made it with the "Dremel" and a 90° gear, an a brand new 3mm HSS Drill.
I've only scratched and made a little tiny Crater.
but this Stud is such hard....

then i have tried a smaller one with carbide edges. (but not new)

And finally i tried to open the other Studs, to remove the Flange, no way,
The Flange looks pretty good but the Nuts and Studs are corroded.

Any tips?
Any hints?
I don't want to remove the Head, because, its hard and very expensive to get Parts here in Europe.

I've this at home:
http://www.innotecworld.com/products...p?productid=84
also WD40, Caramba, Never Seize, and some other penetrating Oil.
I've also a TIG welder (but no way to reach the Stud)
and tiny Grinder (Drehmel)

should i try to grind a Slot in it, and heat it, and then try to get them out?

It drives me crazy to knowing a Leak (small leak) and no opportunity to repair.

Or is there anything that i could smear on it, some magic stuff?
JB-Weld ?! or so

fokker

i've removed the RH Exhaust Manifold, because of Leaking and broken Stud.
Found a second broken stud (Nut was held only by rust)
I could remove all broken Studs and the good Studs, except one.
I've retreaded them. (i think i let em in)

And i've found a Crack at the Exhaust manifold between 3th and 4th cylinder.

Just welded.

tomorrow, i'll buy some studs and Nuts, and then i try to reassemble it.

(it is not easy to TIG weld Casted Iron, but it's possible, with much cleaning and preheating)