I was down at a local shop having a tubular manifold put on yesterday. The stock one came off OK. The new one went on OK also. But when they were doing some final adjustments they broke off one of the four studs from the compressor side of the turbo!! Then when they were taking the manifold off to fix that first broken stud, another stud broke off!! So they were able to drill one of the studs out, but when they tried to re-tap it.. yup, you guessed it... the tap broke off!!!

I'm hoping they can fix it. Otherwise I guess a couple of my options are getting another "hot side" or a whole other turbo set-up. The Evo 6.5TME bolt on has caught my eye right now. I really hope they can fix the stock one though. I've already spent more $$$ than I wanted to!!

 

shops are bone heads. I believe in do it yourslef. Its so hard to brake a stud. was it hot when they were working on it?

 

Did they follow the factory procedure for torquing down the turbo bolts? In other words, 38lb-ft of torque? Did they use high-temp anti-seize on the threads?

Why were you getting a tubular manifold in the first place? I doubt you will see any gains from it at all.

 

I just went through this. I was taking my exhaust manifold off to tap for an EGT probe. I snapped one of the studs off just using a breaker bar to break the nut loose. The other stud I was trying to take off so I could just replace them with bolts, and it stripped out the inside of the hole it was in before it cam all the way out.

I had to drill out the 2 studs, and use a carbide cutting tool with my dremel to bore the rest out. It took me about 2 days. Of course, once I found the right type of drill bit, it made things move along much faster.

I went to Lowes and bought 2 grade-8 bolts with washers, lock washers, and nuts. Dropped the 2 bolts down through the exhaust manifold and put a nut on the underside of the turbine housing. It's been fine ever since.