Exhaust Manifold Studs - Saabnet.com Bulletin Board

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Exhaust Manifold Studs
Posted by Doug W [Email] (#2371) [Profile/Gallery] (more from Doug W) on Fri, 29 Dec 2017 18:25:44
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I just had an indie shop replace my exhaust manifold studs and gasket. The car was nearly undriveable. The lower stud on #4 had failed and fallen out. Exhaust came right out past the gasket near the stud and wafted into the cabin necessitating driving with windows open in 5°F weather. Not good.

My indie found three failed studs, a warped exhaust manifold, and one failed turbo stud. They replaced all eight manifold studs with grade 8 BOLTS. IS THIS AN ISSUE? Evidently they've done this before an many other 9-5s with no ill effects. My garage is too cold now to attempt such a job, besides not having the correct tools.

They also replaced all the turbo studs along with the gasket. The new one they installed is not all metal but has a resilient material in the middle. Supposedly it's better.

The car is an '04 9-5 Aero with 185k miles on the clock. From what I've read on this board, most all 9-5s will suffer at least one manifold stud failure at this sort of mileage. It sounds to me like exhaust manifold stud replacement should be done along with fuel pump and throttle body replacement as part of a 150,000 mile service. For good measure I had the original coolant pump done while the car was in the shop.

We had been hearing ticking noises that went away during warm-up for at least the past 30,000 miles. Recently I detected blow-by at #4 cylinder where the manifold meets the head and also noticed the missing stud. The exhaust in the cabin was the last straw and forced the repair. To me it seems crazy that exhaust manifold studs would fail at 150,000 miles. It's as if the SAAB designers were forced by the bean counters to choose a cheaper and inferior alloy. We had a Volvo turbo with 300,000 miles on it and original exhaust manifold studs.

posted by 75.38.243...

_______________________________________ '04 Aero Sport Kombi '03 Linear 5 spd. Krona Mods, 350 bhp

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