3" Exhaust Install + Broken Manifold Stud = Less power?

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3" Exhaust Install + Broken Manifold Stud = Less power?

Postby awolo » Mon Jul 16, 2012 1:37 pm

Whats up guys.

As many of you know, I spent my weekend outside under my car installing my full 3" inch turbo back exhaust. Well I finally got it all installed. I also did some maintenance and changed plugs/wires (NGK-6RE or something like that)

During this process, I broke a manifold bolt of the stud on the head.

So the car sounds great, spools fine, and makes a solid 15psi...but she just doesn't "go" like she used too.

Would that broken exhaust manifold stud, being pre-turbo, really cause that much power loss?
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Last edited by awolo on Mon Jul 16, 2012 1:53 pm, edited 1 time in total.
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3" Exhaust Install + Broken Manifold Stud = Less power?

Postby celigts » Mon Jul 16, 2012 1:40 pm

Do you have an exhaust leak? Cuz I to have that issue cuz of my shitty gasket and mildly stripped stud. Doesn't spool as well as it should and from what the wideband says its running richer!

Oh and I can get my full boost psi but pulls worth shit. Might be getting like 5-8 psi total
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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby awolo » Mon Jul 16, 2012 1:56 pm

I'm assuming I have an exhaust leak.

I mean, there is literally no bolt on the driver side lower Exhaust manifold stud. You cant exactly start the car and reach in to see if air is coming out either.

This is the only reason I think the car doesn't pull like its supposed to.

Going from a restrictive stock down pipe - cat - cat back TO a full 3" turbo back, you'd think she would have a bit more pull than stock.
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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby toayoztan » Mon Jul 16, 2012 2:19 pm

The car should have more pull with the exhaust, more noticeably up top, and more spool.

A broken stud can cause a bad enough leak (whether acutely now or later after significant warping) to cause loss of power.

I remember when I first bought my '92, I raced it at the track...ran 17's lol. Turns out, had an exhaust leak, warped manifold, and somewhat apparent after a while from a airplane prop sound coming from the area.

That leak essentially acts like a WG left open.

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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby awolo » Mon Jul 16, 2012 2:32 pm

toayoztan wrote:The car should have more pull with the exhaust, more noticeably up top, and more spool.

Bryan


Agreed. Only when I give her full throttle, its like she is revving for really not taking off like she used to.

This sucks. I have a race this weekend and little time to completely tare her apart.


I think i'm going to try removing the stud using a Left Handed drill bit. Another member had good luck with this method. on his AllTrac.
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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby toayoztan » Mon Jul 16, 2012 2:37 pm

Did it snap off clean/flush or do you have a bit of stud left to grab onto or weld onto to make it easier?

If you attempt to do easy-out or lefthand drill, etc. to extract it, heat up the head around the stud to expand the thread, shoot some seafoam deepkreep or pbblaster, let it soak, reheat, and attempt very carefully.

Which stud is it?

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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby awolo » Mon Jul 16, 2012 2:46 pm

toayoztan wrote:Did it snap off clean/flush or do you have a bit of stud left to grab onto or weld onto to make it easier?

If you attempt to do easy-out or lefthand drill, etc. to extract it, heat up the head around the stud to expand the thread, shoot some seafoam deepkreep or pbblaster, let it soak, reheat, and attempt very carefully.

Which stud is it?

Bryan


My superior strength, twisted it off flush with the exhaust manifold.

I'm going to run to the hardware store on my lunch break, buy a left handed drill set, PB Blaster, and a torch.

The stud that broke would be the first one on the right side, when looking at the engine.

NOTE: Im not going to be removing the exhaust manifold. Not sure if I was clear on that.
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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby toayoztan » Mon Jul 16, 2012 2:49 pm

awolo wrote:
toayoztan wrote:Did it snap off clean/flush or do you have a bit of stud left to grab onto or weld onto to make it easier?

If you attempt to do easy-out or lefthand drill, etc. to extract it, heat up the head around the stud to expand the thread, shoot some seafoam deepkreep or pbblaster, let it soak, reheat, and attempt very carefully.

Which stud is it?

Bryan


My superior strength, twisted it off flush with the exhaust manifold.

I'm going to run to the hardware store on my lunch break, buy a left handed drill set, PB Blaster, and a torch.

The stud that broke would be the first one on the right side, when looking at the engine.

NOTE: Im not going to be removing the exhaust manifold. Not sure if I was clear on that.


Yeah, if you don't need to remove the manifold at this point, and can get an extractor/easy out in there, then that should be fine. Just make sure you spend a good amount of time heating up the head. On that note...what manifold gasket do you have? If it's the stock metal one, you'll be fine with the torch. If it's like felpro or something...i can't be too sure on that.

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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby awolo » Mon Jul 16, 2012 3:02 pm

All stock as far as I know. When I was doing the Down Pipe install I did notice that the gasket was metal.

I'm def going to take my time. Remove what I can to make it easier to get in there and just be easy. Worse case it doesn't work and I have to tear everything off, which will most likely create more problems, but you'll have that.

I should have known it was going to break...stupid me.
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3" Exhaust Install + Broken Manifold Stud = Less power?

Postby celigts » Mon Jul 16, 2012 4:17 pm

Could each stud be removed without removing the exhaust manifold? I'd like to replace each stud and grease them up before reinstalling them. Re thread them to be safe and get and crud and whatever out.

I to have the metal sheeted gasket. So it's ok to heat the head enough to remove the studs easier?
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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby awolo » Tue Jul 17, 2012 11:41 am

If you where going to remove them, without removing your manifold, you'd almost have to drill them out, or see if you have enough surface area to grab them with some channel locks. Either way, you'd want to replace them with new studs.
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3" Exhaust Install + Broken Manifold Stud = Less power?

Postby celigts » Tue Jul 17, 2012 11:55 am

Yea for sure. Can the manifold be removed without removing the turbo? Or just easier all at once?
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Re: 3

Postby awolo » Tue Jul 17, 2012 11:59 am

celigts wrote:Yea for sure. Can the manifold be removed without removing the turbo? Or just easier all at once?


From everything i've read, it cannot be removed without taking off the turbo.

Which is why i'm going to try the LH drill method.
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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby awolo » Wed Jul 18, 2012 2:38 pm

Today is the day.

After work, im dedicating my evening to getting this stud out and replacing it.

I need to drive my car and i wanna hear that turbo scream!
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Re: 3" Exhaust Install + Broken Manifold Stud = Less power?

Postby underscore » Wed Jul 18, 2012 3:40 pm

After taking everything off several times I'd said it's probably easier to just remove the manifold and grab the remains of the bolt with some vicegrips after heating the crap out of it. I've also found filing off the threads on part of the bolt so that you're grabbing two flat surfaces can help. When I got my car it had the far left stud broken and that gave it a huge leak and lost the car a lot of power.
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