Club 80-90 Forums

Having had my t25 1.9 watercooled camper off the road for the winter due to two broken studs on the exhaust manifold, i've decided to go for it and attempt to drill them out. I'm guessing as it's a common problem people will know how deep the studs go into the manifold? When i say i've decided to go for it, i'm still pondering whether to do it myself or get someone to do it, part of this pondering is finding out how deep the studs go into, so i know how far to drill into them

Studs are normally about 10mm into the head. When you drill them out you should find an air pocket at the end of the thread when the drill bit breaks through. Grind the stud nearly flush to the head and center punch, then work up through drill sizes. Your need 38mm x M8 stud to replace them with available from gsf for pence.

you have got the engine out so you can drill it square????

Thanks for the replies both. I have yet to attempt this i've been busy lately.
I was going to have a go with a right angle drill and attempt it with the engine in, i haven't the space to drop it, the only other alternative is to get someone else to do it-which will cost £900 with a new exhaust. I may still get someone else to do it, although i have been wondering if i can get at least the one stud replaced with the engine in, it'll give me a chance to replace at a later date.
What do you think?
Thanks

Presumably that 900 quid includes the cost of a stainless exhaust and professional fitting as well as the drilling of the studs?

use bolts not studs imho especially not cheap studs

genuine studs from VW N 014 443 12 50p plus vat each

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