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broken exhaust manifold studs Posted by skibumm100 [Email]  (#3255) [Profile/Gallery]
(more from skibumm100) on Mon, 15 Aug 2016 09:32:54
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Finally finished this job last night. After too many weekends of frustration, I finally put this one to bed. The patient is my 96 black Aero 5-speed. I bought this a couple months ago from a Saabnet classified listing located in Maine. It had a blown exhaust manifold gasket so it wouldn't pass inspection. Three broken studs. Two were flush with the head and one broke at the nut. I decided to do it myself rather than taking in to my indy. I started off on the wrong foot by drilling them off center so badly they wouldn't loosen up. Then I broke off a bit in one of the holes. That was the low point. I got a carbide dremel bit and ground the broken bit and the broken studs out of the holes. Had to use a mirror for most of this work. The stud that was sticking out came out stubbornly after welding a coupling nut to the remaining stud after about seven tries. For the two holes I totally bunged up I bought some SS 8mm EZ-inserts from McMaster-Carr. I drilled them out to 27/64's with the manifold in place and tapped the holes to 1/2-13 NC. I would recommend getting a bottoming tap as I was using a plug tap and I barely had enough threads in one of the holes to screw the insert flush. Plug tap first, then use the bottoming tap. In fact I ended up taking a grinder to make it completely flush after it was lock-tite'd in place. Save yourself the trouble and get the correct taps and bits from McMaster as you most like will never find a bottoming tap anywhere unless you have a Fastenal store nearby. Once the inserts were in place I cut 8mm 18-8 SS threaded rod (also McMaster-Carr) to length (I think it was 3-1/8" long) so I could double nut the manifold in place. I used copper never-size and double nutted with brass nuts. No problems after torquing them to 240 in-lbs. Started it up and all is well. Time to go get it inspected!
posted by 73.249.195...
_______________________________________ long-time listener, first-time caller Saab glutton for punishment
, Mon, 15 Aug 2016 09:32:54 <-- Viewing This Message, Mon, 15 Aug 2016 13:01:17, Tue, 16 Aug 2016 08:26:06
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