Broken Stud (me included!)

[rjking]

Started hearing exhaust leak on my '02 LT and after investigating found one of the exhaust header studs on #1 cylinder broken off in the head. I assume I can just drill it in place and back it out with an "Ez-Out"...Anybody else ever had to do this? I sure don't want to have to pull the head and put it on a drill press!

R J King

[STARFIGHTER]

Be very careful............
I had a crack in my header, and found a broken stud when removing it....
trying to get it out, I broke the easy out in it..................................
ended up with a new head and fewer $$.
The header was cracked in between inlets and couldn't be welded so,
I replaced it with a more robust Remus system, but went through quit alot before I got the sound level down to where karen would ride with me.........

[messenger13]

I haven't had any experience with broken studs on the LT...but I have had plenty of experience with EZ Outs and the like. I like the straight-fluted type, rather than the twist-fluted (reverse drill bit) type. In other words...I like the type where you drill the hole(s), tap the EZ Out into the hole and remove the broken stud. (Using a LOT of penetrating oil, of course.)

Here's a link (http://www.team.net/sol/tech/BrokenBolt.html) that you may find useful. I happen to agree with most of his statements.

Oh . . . and good luck. :cool:

[mneblett]

Started hearing exhaust leak on my '02 LT and after investigating found one of the exhaust header studs on #1 cylinder broken off in the head. I assume I can just drill it in place and back it out with an "Ez-Out"...Anybody else ever had to do this? I sure don't want to have to pull the head and put it on a drill press!

R J KingBefore drilling out, drop the header -- If you're lucky, you may find enough of the stud still sticking out of the head to be able to get a grip on it.

[murray]

If the stud is flush and you cant grab it don't even try a EZ out. The EZ out will surely break. Consider a left handed drill bit the stud may free up . Option 2 if you know a good welder have him tack a weld on the stud keep building up the weld then grab it and back it out.

[McAllister]

I had the same stud break on my 03. The studs are not put in very tight. If you can get a pair of needle nose vice grips on the broken end it should turn and come right out. You will need to remove the exhaust system to get access. And you will need to replace all four gaskets between the head and the exhaust.