DG exhaust stud replacement - can it be done in situ?

[ghost123uk]

I'm only here cause it's raining. Never mind, first rain for ages and the garden needs it. Small text cause it's off topic

[Hoopy_Frood]

I've got a newish vw speed shop stainless exhaust - if it's just the old exhaust system that's the problem, I might as well use the grubs - again, I think that's a top tip. (A real one though not the Viz type).

Cheers
Iain

[itchyfeet]

Hard to see from this pic if the 'j tubes' are seperate, assuming they are then studs should work

http://www.vwspeedshop.com/product.php? ... 499&page=1" onclick="window.open(this.href);return false;

[ghost123uk]

Hard to see from this pic if the 'j tubes' are seperate, assuming they are then studs should work

http://www.vwspeedshop.com/product.php? ... 499&page=1" onclick="window.open(this.href);return false;

Fitted one of those onto the Hi-Top van we recently sold. iirc the J tubes are one piece.

[pionte]

Because getting the early system all on studs is difficult
It's not an issue on late exhaust systems the bends are easier

aha , that would explain why I struggled... I assumed that maybe I hadnt drilled one of the holes exactly true..it did go on though with all studs.The engine was out at the time so perhaps I had move room to exert more force . I hadnt seen these with the hex drive so used the 2 nut technique.Good shout Itchyfeet.

[xpress]

How do you get the original studs out?

Also when winding in new studs with the allen key, do you need some threadlock on the ends?

[itchyfeet]

How do you get the original studs out?

Also when winding in new studs with the allen key, do you need some threadlock on the ends?

Getting rusty studs out can be alot of pain, it really depends how bad they are, if they are servicable maybe best leave them, if they are stripped or snapped then there are a load of methods ranging from clamping tools welding nuts on and drilling out.

You ask lots of questions but dont give much detail of whats holding your exhaust on and what you have done so far in terms of trying to remove them.???

Dont worry about locking new studs in, having them rattle out is unlikely as long as they are torqued and really the least of your worries, id rather that then them stuck in.

[T25Convert]

I also have an early exhaust, and went down the M8 - M10 route, using the (strangely expensive) step studs, but whilst the engine was out.

As itchyfeet notes, its not the fitting the exhaust that is the issue, but its almost impossible to get it back off again, the J tubes stick on the connection to the box and its a nightmare.

To make it worse, with the 10mm step studs, when you find yourself stuck you can't even then wind the studs back out through the flange, as the flange only has a 8ish mm hole in it, so you are well and truly stuck then.

If I did it again it would be helicoil I think!

Cheers,

Alex

[xpress]

But alex with the hex headed worm studs you could just turn them out and drop the j tube, but it sticks to the muffler connecting piece?

I just have to replace the j tube but it's broken near the muffler connection, so I have to get the j tube off the studs, the old nuts off and open the muffler connecting piece to fish out the broken off piece! Regarding early exhaust disassembly problem, surely you could tap off the j tube from the studs with a block of wood on the bend of the j tube to free it from the studs and the muffler end?

[itchyfeet]

But alex with the hex headed worm studs you could just turn them out and drop the j tube, but it sticks to the muffler connecting piece?

We are going round in circles
look at my pic on the last page there are two locations where you cant wind studs out as they will hit the pipes

xpress, if the j tube is knackered why not just cut it? Then pull it off the studs, then pull the remaining bit from the exhaust (as already sugested)

[CovKid]

xpress is noted for his splatter type questioning - gets excited I think. What we need is pictures fella. Without them this is like playing battleaxes in a very dark cellar.

[xpress]

Ok I've been out there in the abyss! Thanks for your patience!

Can I get an irwin 11mm bolt grip and a spanner onto that lower nut without cutting the pipe!

It's touch and go! Maybe I might go the weld patch up option for now! Pictures coming!

[xpress]

[itchyfeet]

Lower one is a bolt cant see the upper one but probablt a bolt also
ideally get plus gas on them, soak tgem several times for a few days first then have a go unscrewing them.

http://www.ebay.co.uk/itm/Plus-Gas-Lubr ... 53fb45593b" onclick="window.open(this.href);return false;

[CovKid]

And scrape out all the rust/crud so you can see whats left.