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Exhaust leak help
PostPosted: Tue Oct 01, 2013 7:10 am Reply with quote
Yotaoffroad27
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kind of a long storey so I will just tell you what I have done.

My DD- 96 Taco 2rz w/ a broken exhaust stud.

Last friday I spent a few hours trying to get the stud out. I welded 7 or 8 nuts to the stud but each time the weld broke.. Used a smaller drill and drilled some of the stud out, and then broke an easy out. Lucky I was able to get the easy out, out. Then I just kept stepping the hole up till it was 5/16. I then tapped it and put a bolt in it.

Now the problem is I think the threads are just pulling out as I stug up the bolt. also, the hole is slighty off center, so I cant go too much bigger or I will be into the head and the stud wont fit throught the hole in the header.

My next bright idea would be get some threaded rod and just run it in the hole. Let it make its own threads, then weld it to the left over stud.

I am getting a CEL- P0420. Showed up after I broke the stud..


HELP!!!

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PostPosted: Tue Oct 01, 2013 8:18 am Reply with quote
DAWGTOY
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is it a stud coming out of the head or where the exaust manifold goes to the exaust pipe?

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PostPosted: Tue Oct 01, 2013 8:21 am Reply with quote
Yotaoffroad27
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DAWGTOY wrote:
is it a stud coming out of the head or where the exaust manifold goes to the exaust pipe?


its a stud coming out of the head. rear most stud.

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PostPosted: Tue Oct 01, 2013 9:55 am Reply with quote
DAWGTOY
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so it's in aluminum. about your only fix is a heli coil.
you'd have to pull the manifold to get to it.
really the only way to do it right.

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PostPosted: Tue Oct 01, 2013 10:14 am Reply with quote
Yotaoffroad27
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DAWGTOY wrote:
so it's in aluminum. about your only fix is a heli coil.
you'd have to pull the manifold to get to it.
really the only way to do it right.



There is still part of the stud in the head. If I can figure out a way to get the stud out, I could heli coil it, but since I cant, im doing the best with what I have.

I have had the manifold off a few times trying to get the stud out.


Could I run a stud or threaded rod into the head, and tack weld it to the old stud. That way I can tighten the nut to the gasket.


this engine has 225k on it. I cant really see spending much money on it......

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PostPosted: Tue Oct 01, 2013 11:46 am Reply with quote
DAWGTOY
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so is there any stud stickin out?
if so welding a threaded rod to it might work.
if the studs broken off below the surface i don't know
how you'd weld anything to it.
theres not another threaded hole close by is there? like within an inch?
if there is you could make some kind of bracket that would
tighten down on the manifold flange using a bolt in the
unused hole. that make any sense to you?

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PostPosted: Tue Oct 01, 2013 12:06 pm Reply with quote
Yotaoffroad27
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DAWGTOY wrote:
so is there any stud stickin out?
if so welding a threaded rod to it might work.
if the studs broken off below the surface i don't know
how you'd weld anything to it.
theres not another threaded hole close by is there? like within an inch?
if there is you could make some kind of bracket that would
tighten down on the manifold flange using a bolt in the
unused hole. that make any sense to you?



The broken stud is now flush with the head, but I can run a smaller bolt/stud into the hole I drilled and tapped. The hole wasnt dead center of the broken stud, so there is still some steel left next to the hole. (I have tried knocking it out, but Im not having any luck)

Basically I can run the threaded rod in the hole, tack the threaded rod to the old stud so maybe between the tack and threads I can get the nut tight and seal the exhaust leak. My truck due for inspection in November..

Make since?

I had thought about pulling the head sending it to a shop and having it taken care of, but then Im out 150$ or more at a machine shop, plus gaskets plus gaskets.. and I still have a noisy motor with 230k on it...

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PostPosted: Tue Oct 01, 2013 1:45 pm Reply with quote
DAWGTOY
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jb weld Very Happy

dollars make cents.



what your talkin about just might work. can you still get the manifold
on with the new stud not in the correct spot? might have to elongate
the hole a little.

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PostPosted: Tue Oct 01, 2013 1:53 pm Reply with quote
Yotaoffroad27
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DAWGTOY wrote:
jb weld Very Happy

dollars make cents.



what your talkin about just might work. can you still get the manifold
on with the new stud not in the correct spot? might have to elongate
the hole a little.


I have a bolt in it currently, but I just cant get it tight. I might try and make the hole a little bigger and tap it with a fine threads and see what happends.

I just worry about the weld making a weak spot on the "new" stud and it breaking off....

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PostPosted: Wed Oct 09, 2013 8:41 am Reply with quote
Yotaoffroad27
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Just to put a cap in this.

I picked up an o2 sim and got ride of the code.

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Exhaust leak help
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