Section 2: Removal of the Exhaust Studs
Each head has 4 studs that are used to bolt the exhaust to. These are particularly prone to corrosion due to the heat that they are exposed to and they can be difficult to access when the engine is in the van.
I have some previous fun with exhaust studs when I fitted a Stainless Steel exhaust to my old DG engine. I managed to snap a stud and had to drill it out and helicoil (use a threaded insert) to fix the problem whilst underneath the van.......good times!
The stainless exhaust will be going on this engine once it has been rebuilt therefore I want to remove the old steel studs and replace with new M8, 40mm Stainless Steel studs (approximately £1 each off eBay, 8 required).
There is a technique for removing studs that was mentioned when I asked the question on here but nobody explained how to do it - I had to ask YouTube.
Here’s a very quick photographic guide.
Tools Required: 2 x 13mm Open Spanners, Plus Gas or other Releasing Fluid (Copious amounts), Possible heat source such as blow torch, M8 Nuts x 2.
Time Taken: 30 Minutes
Studs have no heads on which to put a spanner, therefore we must create one. If possible, soak the base of each stud in plusgas for a few days before attempting to remove them.
Screw first one of the M8 nuts onto the stud, followed by the other. Then, unscrew the lower one and tighten the upper one until they meet
Then, take both spanners and work them in opposite directions - loosen the lower nut and tighten the upper nut
This will ‘lock’ the two nuts together. The lower nut can then be used as a bolt head - make sure your spanner is just on the lower nut and as you unscrew the stud will unscrew from the case.
This technique may not work initially as there can be lots of corrosion - cleaning with a wire brush, plusgas followed by more plusgas then a bit of plusgas, or some well directed heat can all help.
WARNING: Many many exhausts studs are corroded beyond hope and will snap. The Wiki covers various methods for removing broken studs so I won’t duplicate.......however, if one does snap, it isn’t the end of the world and perfectly satisfactory repairs can be made with a little care and attention.
I was extremely lucky in that all 8 exhaust studs came out incredibly easily - this suggests that they have been replaced relatively recently. I fully expect to find that some of the holes have been previously helicoiled once I clean the heads up and have a closer look.
New Stainless Steel, M8 40mm studs on order - I tend to buy the ones that can be screwed in with a hex or Allen key.......saves all this messing around with spanners and nuts.
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