Exhaust has threaded bolt hole on Manifold

[climberjim]

I was getting some complaints from my better half, saying there were fumes getting into the back of the cab. The complaint was greeted with the usual "Uh".

A few weeks later after the exhaust was sounding like it was blowing a little, I thought I had better have a look.

The problem looked straight forward there was a gap at the top of one of the exhaust attachment points, so easy fix. Just tighten the bolt and replace the gasket jobs a good un.

Not so the bolt was completly loose and when I removed it, it came out a little to easily to my horror the bolt had removed all of the thread from the inside of the maifold.

At this point I realised the job, as usual would not be as straight forward as I first thought. So I ran it down to a garage who say they will need to remove the engine to re-thread it with a helicoil thingy.

Has anyone ever had this happen to their van? and is there a way around taking the engine out and saving me a shed load of cash?

I really hope that someone can help, you guys have dug me out of many holes before.
Cheers Jim

[Lobey]

I had similar problem recently when having new exhaust fitted - engine had to be dropped to reach rear manifold bolt holes for re-threading. Will not be best pleased if anyone suggests a more simple fix here - extra work cost me about £150...grrrr

[Aidan]

depends which stud has stripped but access is pants to try and do a repair as you need to get the exhaust off and then get in with reamer and tapping tools and insert tool whether using Timesert or helicoil and if you need to drill well there's no space for a drill is there ? so engine out will be easier probably - while it's out get them to take complete exhaust off and replace all the studs and bolts so that next time it has to come off you stand a chance without removing the engine
ps stud was probably stripped in the block previously and someone has tried to plastic metal it back in in order to avoid doing the job properly chances are there will be other bodges

[climberjim]

Ok fellas thanks for your replies. I will book it in at the local vee dub shop.

Jim

[stoneageman]

Hi Jim,

How did you get on with this? How did you resolve, if at all?
I have the same problem, i've had a quote £900 to take old exhaust and replace with stainless, but can't afford that at the moment.
I thought i would have a go at doing it myself by using an angle drill to drill out the studs, it's the back ones or front as you look at it.

Just wondered if you had any advice from your experience

Cheers

Ade