Club 80-90 Forums

Hi All, new to the T25's as I've just joined the ownership club. Have an 84 converted caravelle with 1.9DG engine.
It has a 'sports exhaust' but I did think it was a little too noisy and on investigation one of the exhaust studies is broken - no nut in sight and something is there if I poke the hole. I see there are some wiki ideas about welding nut on the broken stud and removing, but my main question is, "is it best to remove the cylinder head from the engine and do it on a bench, or can it be done in situ? For reference it's located on nearest right hand side if looking from back of van to the front. Thanks for any comments

deffo try it in situ first
removing a head is a last resort and easier to remove the whole engine before resorting to removing a head.

I agree, dead simple with the engine out.
Kenny.

I replaced one recently. I have done a few on various vehicles and you will be lucky to remove it. Best to drill it out and fit a helicoil. Rough method is this:

Cut off stud flush or file smooth, centre punch and drill a small hole in the middle (Hint: Get a new stud so you can see how far they screw into the head. Mark your drill with some tape to ensure you do not drill in too far). Slowly enlarge the hole until you can drill a hole with the drill that comes in a helicoil kit, tap thread, fit insert and hey presto! Don't worry if you drill a little off centre. If you do, often when you break through the edge of the existing stud it will come loose. I still recommend the helicoil afterwards though as the thread will be damaged.

If you drill

this is in wiki but It's my hand

One last thing. Don't be tempted to use a stud extractor, at least not the 'easy out' type which has a tapered end you put into the hole drilled into the stud. It will almost certainly snap off and then you have a real problem!

It is possible to buy drills that cut in an anticlockwise direction. I have seen these recommended as the cutting action is attempting to undo the stud rather than do it up. You can get them on our favourite online auction site. It seems a good idea but I have never tried them.

My trusted method is to weld a bar to the end of the stud and unwind it whilst still hot, Sometimes the weld breaks and may need a few attempts.
Kenny.