Hey guys, so I was trying to replace my manifold and whilst removing the studs one of them snapped just below level I know there are various options but if it comes to drilling it out, is it ok to go all the way through these studs? Is there anything behind them that it's not ok for the shavings to fall into? If it makes a difference it's one of the top row (think there's oil galleys behind the lower ones?)
thanks

 

Which stud broke, 3 of them of them go through to oil drain back ports. The 2 big ones on the outside, and the top center one IIRC.

 

Terrible quality photo, but hopefully clear enough, it's this one

Bolt shown clearly in pic is removed, it's the one furthest to the left that's snapped (small bolt)

 

Furthest to the left, the one that's clearly sticking out in the photo is removed

 

That one doesn't go through. I've had that stud break on me too.

 

Crackin', thanks!

 

I had the right big one break on me, should I leave it alone, try to drill it out carefully or have a shop do it?

 

Drilling scares me, especially hand drilling. Ford made some engines where the studs always break, its routine maintenance to replace them. The mechanics don't drill them. I suggest finding a Ford mechanic.

 

Remove the head, accurately center punch the broken stud, and use a left-hand bit on a drill press to drill it out to tapping diameter. Re-tap the thread, then use stainless replacement ARP studs with copper anti-seize.

 

 

 

Remove the head because trying to do this with a hand drill will more than likely cost you a new head. If you have the cash go for it!

 

I've learned that normally, when it comes to exhaust- it's best to use a torch and heat up the nuts BEFORE you try and remove them. It may be un-necessary, but the little bit of extra work ahead of time can save you a ton of work later.

There are inductive heating tools that are easier to use if you don't have access to a torch. Easier and safer to use these.

 

Your easiest bet is try welding a nut to the stud. Build up material thru the nut onto the stud and try taking it out with the ratchet or wrench. Use a little heat on the head too directly around the stud and it should come out. Might take a few try's but better than pulling the head.

 

There isn't anything sticking out to weld the nut to.