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Re: stronger exhaust manifold studs?

Any idea on how to remove a OM-stud broken 2mm below head surface, - and
what to replace with ?

The OM is cracked, and i'll be ordering a new two-piece soon.
- Will i have to drill the holes larger ?
- Will that impact durability ?

Kenn Thyrsted
'87 200(t)Qavant (On Jack Stands)

----- Original Message -----
From: Phil Payne <quk@isham-research.demon.co.uk>
To: <dmr@kwic.com>
Cc: <quattro@audifans.com>
Sent: 18. september 1999 17:47
Subject: RE: stronger exhaust manifold studs?

> In message <01BF0171.21AD4900.dmr@kwic.com> Don Muirhead writes:
> > I found a couple studs broken on my coupe last weekend and picked-up a
> > handful from the Dealer today.  The ones I grabbed today are the same as
> > the ones that were replaced under warranty 13 years ago and at only a
> > ea. (CDN).  So I'm not going to worry about the studs breaking for at
> > 10 years.  But that's only my opinion and my $0.75
> Broken studs are a real problem on the turbo cars, perhaps because the
> weight of the damn thing is entirely carried by the exhaust manifold.
> I've made two major advances in the last year.  One was acquiring a
> FACOM 287B.8 stud remover.  This device slides down over the stud and
> grips it using three internal rollers - the force applied to the stud
> during removal is coaxial with the stud and thus old studs are less
> tempted to snap off.  It also helps if you apply lubrication as soon as
> you have movement and screw the stud back in and out to spread the oil
> down the threads.  Note my criticism of the Dialynx manifold in this
> regard - in contrast with the Audi original, it's impossible to get a
> socket onto four of the nuts from above with the Dialynx beast.  You're
> left with a 12mm or 13mm 6-point box (ring) wrench (spanner) from the
> side, with an awful lot of shear component.
> The second major advance was a FACOM 885 stud remover kit.  It's a
> 25-part kit comprising drills, locating sleeves, removing splines and
> driving nuts for the splines.  It really is _magic_ in operation.
> So far, on 100,000+ mile ur-quattros, I've taken off about ten manifolds.
> In every instance, at least one stud broke - but I've got it down from
> an average of four to only one on each of the last two.  Both #5 upper,
> as it happens.
> But as before - I'd rather have a stud snap than drag out the threads
> from the head.
> --
>  Phil Payne
>  UK Audi quattro Owners Club
>  Phone: 0385 302803   Fax: 0870 0883933