1st post, re: exhaust manifold flange stud removal

Hello, all. I just completed replacing the clutch on my '01 (209K miles), which went successfully. I followed most all the steps in the Haynes Manual, including the one for removing the front exhaust pipe. When I went to reinstall this front exhaust pipe though, I ran into a problem. The flange at the front of the exhaust pipe bolts onto the rear flange of the exhaust manifold. This rear flange has 3 studs, onto which the exhaust pipe flange is secured with three nuts. After removing the nuts, apparently one stud's threads were stripped, due to corrosion. When trying to reinstall the exhaust pipe, two of the nuts successfully threaded onto their studs, but the third would just spin, unable to grab onto anything.

I'm not too thrilled with the prospect of removing the exhaust manifold to remove the stud, but I did notice this stud has external torx fitment on its end. Does anyone know the size of the external torx socket needed to remove this stud? Anyone ever try removing that stud this old by reaching up with an appropriate socket on an extension - is it going to break off in the flange? The sound coming from the exhaust pipe is a little loud on acceleration, but overall not too bad. Any advise is welcomed and appreciated.

 

I don't know the size but have had to change a few over the yrs.
Good luck and use lots of penetrate oil but if it didn't spin out with the corroded nut on it's prob. drill time.

 

Just weld a nut on the end, you'll have better luck going that route than trying to use a 19 year old corroded torx head

 

Last resort would be to take it to an exhaust shop. They can cut out the old flange and weld on a new one for you. Save you time and stress. It’s not that expensive to do either.

 

This happened to me on my 2003 during a clutch swap. Ended up drilling it out...that sucked and cost me a 12 pack at the shop!
But seriously, soak that shit in Kano Kroil for a couple days. Then try the external torx.

 

I'm giving this suggestion a try, first (and last, I hope). I've ordered a can of Kroll, and a set of external torx sockets. I'll post after trying it. Plan B guess will be to pull out my little Bernzomatic oxy/MAPP torch kit and apply some heat. If neither work, guess I'll have to pull the exhaust manifold and weld a nut. I am just afraid taking out the manifold will give me several more stripped or broken studs. Thanks for all the ideas. I'll let you all know.

 

I see this turning into a project if you live any where you have winter.

Meaning snow and Ice winter chemicals .

It is the stud that is stripped and not the nut ?

I have cleaned several studs up with a thread chaser to work again.

Best of Luck

 

You can't get welder in there with the manifold still on the engine? That torx bit method has a slim chance of working. Not trying to be pessimistic just realistic. Exhaust work blows, pun intended.

 

Heat and wax are a good combo. The penetrant will flash off, the wax wicks into any crevice.

... plus @6 gearT444E ’s idea for some extra leverage.