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Seized exhaust stud

Discussion in 'XJ Technical Chat' started by AWHH, Jan 12, 2022.

  1. AWHH

    AWHH New Member

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    hello everyone

    I’m new to this and have a question about exhaust stud bold extraction. I was removing the exhaust and managed to break off the nut and bolt. Luckily it broke off with plenty of stud remaining. I tried getting it off with vice grips and penetrating spray but this things not budging.
    My plan is to slot the end of the bolt with a dremmel and use a flat head to back it out.

    is there anything else I can spray on it to help it move? My fear is that it will shear off and I’ll be hooped.

    thoughts?
     
  2. Dan Gardner

    Dan Gardner Active Member Premium Member

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  3. Franz

    Franz Well-Known Member

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    You could use a MAP gas torch to heat the area where the broken stud enters the head. I used that on my engine to remove the stud on the cylinders that located in the front of the crankcase.
     
  4. tabaka45

    tabaka45 Well-Known Member

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    I doubt that a flathead screwdriver will work if vice-grips don’t. I would try the heat treatment Franz suggested first. If you have never tried heat you might want to enlist the help of someone who has.
     
  5. RonniN

    RonniN New Member

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    The best thing with broken studs is to weld a nut to it, and then unscrew, the heat from the welder will most of the time loosen up the seized stud. :)
     
  6. JBurch

    JBurch Active Member

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    Heat the area where the stud enters the head is a good idea, as is welding a nut onto the remains of the stud, it gives you something to get a hold of, don't be surprised if you twist the nut off, it happens ( I had a broken water pump bolt on my Honda CRV, took me 3 try's to get it). One thing you can do as prep is to heat the area around the stud and then wack the end of the stud with a hammer; object here is to break the galvanic bond between the steel stud and the aluminum head.

    Let us know how it goes.
     
  7. a100man

    a100man Well-Known Member

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    +1 on welding and heating. When heating it has to be HOT hence MAP gas or similar - propane alone won't cut it.
     
  8. Dan Gardner

    Dan Gardner Active Member Premium Member

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    Has anyone used those type of stud extractors? Let's just say if a guy didn't have ready access to a welder, would heat plus one of those extractor tools be a good option?
     
  9. Franz

    Franz Well-Known Member

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  10. Scott I

    Scott I Member

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    I third the weld a nut to the stud. I picked up a cheap China DC stick welder years ago and it has come in handy for small jobs like this.
     
  11. Franz

    Franz Well-Known Member

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    Certainly worth a try if there are no obstructions. I have not used them Dan.
     
  12. ManBot13

    ManBot13 Well-Known Member

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    For spray, I'd vote for Kroil unless you've already used it. Hard to tell if it's actually prevented me from breaking rusted/seized bolts, because since I learned about it, it's the first thing I do. And maybe it's bad sample size, but I can't remember it not working.

    Shouldn't hurt to add it to the other options above.
     

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