Best Way to Remove Broken Exhaust Manifold Studs?

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In this video we go over another popular technique to removed stuck broken bolts and studs using welding.
These are the Parts and Tools I recommend:
Thread Chaser-
amzn.to/2E5RLPN
Lincoln Weldpak 140 Welder (very popular unit)-
amzn.to/2KtLihr
Best Welding Wire-
amzn.to/2OZl9I9
My Company BSG Automotive offers Auto Repair services in the greater Chicagoland area.
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www.bsgautomotive.com
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BSGautomotive
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My company RU-vid Channel- BSG Automotive providing repair advice on makes and models other than Ford: ru-vid.com
Disclaimer:
The information, demonstration and any content contained in this video is for informational purposes only. The user and BSG Automotive (hereinafter “FordTechMakuloco”) makes no warranty, express or implied, regarding the effectiveness or safety of the contents of this video. In no way should the contents of the video, including the tools used, be repeated or tried by anyone. Viewers should only seek the help of a trained professional located at a licensed auto repair shop for any fix, modification, alteration, or any change to their vehicle. FordTechMakuloco shall not be liable for any injury, damage, or loss to any person or property that may result from use of the tools, equipment, or any content contained in this video. In addition, there is no way to guarantee that the video is not altered or modified or is not in the final form submitted by FordTechMakuloco and therefore, FordTechMakuloco does not warrant that the video is unaltered or not modified. The links on this video to products are for informational purposes only and in no way are an endorsement of the safety or effectiveness of the particular product. Viewers understand that anything contained in this video or linked to or from this video is the sole responsibility of the viewer and in no way provides an express or implied warranty as to the safety or effectiveness of any linked tool, product, or video. Therefore, viewer agrees to release, waive, and discharge FordTechMakuloco or anyone affiliated with FordTechMakuloco, from any and all liability, claims, demands, actions, and causes of action whatsoever arising out of or related to any loss, damage, or injury, including death, that may be sustained by the viewer, or to any property belonging to viewer, regardless of whether the loss is linked to the use of the contents of this video, or otherwise and regardless of whether such liability arises in tort, contract, strict liability, or otherwise, to the fullest extent allowed by law.

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5 фев 2018

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Комментарии : 392

@FordTechMakuloco 5 лет назад

These are the Parts and Tools I recommend: Thread Chaser- amzn.to/2E5RLPN Lincoln Weldpak 140 Welder (very popular unit)- amzn.to/2KtLihr Best Welding Wire- amzn.to/2OZl9I9

@martingonzalez6504 5 лет назад

Hi FTM, do you ever have a problem with a timing guide dowel broken? I'm having that problem right now and I don't know what to do, can you please give me an idea of what to do? I really appreciate you help.

@martingonzalez6504 5 лет назад

Sorry, I forget to mention,07 expedition 5.4

@JT-un7dc 4 года назад

Hey there, do you use flux wire or non flux wire for this weld?

@pospc2 4 года назад

@@JT-un7dc I'm pretty sure he said flux core during the first few minutes. May want to rewatch again to verify.

@pospc2 4 года назад

I know what my method is going to be since i have a manifold leak on mine. Drive it till the rocker arm noise ruins my engine, ignore the manifold leak till that happens. Send the vehicle to the scrap yard. Drive one of my other vehicles till i find a japeneese replacement for my suv. Then buy a 4 runner or qx56 or similar and happily never own a ford again. None the less I thank you for showing this method and I am sure one day i will find it useful. Just because i am not a ford guy doesn't mean that i have any hate for anyone that is. I find ford to be difficult but i am more of a toyota/Lexus or Nissan/Infiniti kind of person. Btw if anyone wondered why I own a Ford but dislike working on them, my wife found it while she was in the hospital after having our child and liked it. Me being the nice husband i am, went and bought it and then the following day picked her and my child up in it. I bought it because she liked it.

@venomx4093 6 лет назад

Welding is a good trade to know. I've been welding for 18 years for my current employer and I do it on the side at home. I taught my 13 year old son how to weld at the age of 9. Currently teaching my wife the trade as well. As far as your technique goes, whatever works, works. You're not building rockets with all of the red tape hoopla. Great job!

@tapia79r4p 6 лет назад

I just used this method on my 2008 F250 V10 King Ranch. The center studs on both sides were hard to get and I broke easy outs inside of them, so I had to get my Mig welder out. One thing to keep in mind about welding on any vehicle, is to make sure your battery is disconnected so you don't fry and computer modules, systems, or radios. As a ground for welding, I just simply installed a new manifold stud back into the head and clamp on to it. Aluminum is a good conductor. I struggled, but did not have to raise the engine like Alldata stated

@josephtavaglione5670 5 лет назад

Awsome tip and it works amazing. I did it alittle different every stud was stuck in the head. Welded nuts on the studs heated the studs with torch until cherry red and presto. They all came out and didnt have to drill 1. Also I did this on the truck. THANK YOU SO MUCH for the tip.

@jerrybradshaw9879 4 года назад

In the past I have used a similar process by first welding a heavy flat washer followed by the nut. Sometimes have better luck getting good penetration on stud by not having to weld in a hole. Sometimes welder wants to arc to side of nut rather than stud. If you encounter a problem,it's easier than having the nut twist off and having to clean out hole to begin the process again.

@russ_vee_jr4199 Год назад

I used a Fender Washer welded to the Stud or Nub, then a Large Nut centered on the Washer and welded to the Washer. A Nut twice the diameter of the Stud allows for plenty of material to be welded to both the Stud/Nub and the Washer. A correctly sized Fender Washer will protect the head surface and provide good clearance to weld the nut to the Stud/Nub. The Large Nut allows for plenty of weld material to be added to the Washer and the material on top of it. I did six on one side a few years ago. Ford had driven the studs so deep into the head that the non-threaded fat section of the studs were actually grooved by the ALU opening.

@tredog500r Год назад

I struggled for 2 nights trying to get a nut to weld on but couldn’t. I got some big flat washers and did what you said. Got 3 out in about a total of 25 minutes. Thanks for posting this!

@rodv46 4 года назад

I used your technique today to remove 3 broken exhaust studs from a 3.4L Chevy V-6 and it worked perfectly. I'm very thankful for this video as I had exhausted (no pun intended) all the other options I've used in the past so I started looking around RU-vid for other idea's and most were methods I had already tried until I happened upon yours. I was a little apprehensive at first but it worked so well it was like taking candy from a baby (never thought I would use that term in conjunction with removing broken studs). Anyway, thanks again for posting the video and sleep well tonight knowing you helped a fellow gearhead out of broken stud hell.

@cgb1776 4 года назад

Another outstanding video! The two rear studs rotted off my 2010 5.4l, and the two front studs snapped while trying to remove them. Drilling the rear studs and trying an extractor failed. All four studs were really stuck in the head and getting a drill up front was not going to happen. Using my mig welder to build up a nub on the studs then welding a nut on the stub got the job done on all four studs. The job is a pain the ass but the cost saving is huge. I was very reluctant to try welding as I figured I would really mess things up and have to replace the heads. All I can say is trust in your ability and go for it. Thank you so much for your videos, they are life savers!!!

@thearrow5793 6 лет назад

I was watching yours videos long times ago...your are great man and your are number one and I’m proud of you......thank you and god blessed you......keep going.....

@greasee.monkey7224 6 лет назад

I've been using this method for years. So much more effective than a drill and stud extractor. I spend a fair amount if time cozied up to 5.4's, so anything to make life easier is appreciated & utilized.

@frankgrimes591 6 лет назад

Thanks for the work on my ecoboost F150! Cool to see it in the background at your gorgeous new shop.

@hpds1145 4 года назад

Thank you so much for this video and tip. I had known about and have welded nuts onto broken studs, but never had to deal with a stud broken sub-flush inside the head. It took me three tries to get it right - the third time I sanded the top of the broken stud, and built it up enough to get a nut on it, and welded the nut on it, and it came out. Save me a lot of time from drilling it out. I am replacing the exhaust manifolds on my 2002 F150, 4.6L, and all the studs except for one, had to have nuts welded onto them. The one that broke sub flush, broke after I welded a nut onto it. I would never have considered the fact that the weld would not stick to aluminum. Thanks again!

@misterfixit08402 3 года назад

Very helpful and informative information brother, they are getting tighter and tighter with less and less room, right angle drill a must, so tired of drilling in almost impossible to reach areas, but after almost 20 years of trying different techniques this is definitely one of my favorite, thanks for the vids, keep up the good work and keep wrenching, nothing like diagnosing and fixing something nobody else can or will, you know everybody's a mechanic.

@joesc641 6 лет назад

I've been using Lincoln/Miller stick and wire feed welders for over 40 years. Can't remember ever having a problem. Needed a new one for home use but didn't want to spend big bucks. Purchased a Harbor Freight and it works. I wouldn't recommend HF for shop use, but for a once in a while home welder it works just fine.

@tommyweese5697 8 месяцев назад

We have a bunch of miller welders in my diesel shop, and I’ve been laughed at every time I’ve gotten out my dinky little titanium flux welder. But honestly everybody in here has stolen it for one thing or another on these smaller jobs and broken bolts. This welder has its place

@torrisrare5626 4 года назад

Thank you. I just removed four broken bolts from a set of ls heads. Your method worked great!!!!

@reecebrodersen4433 4 года назад

Something so satisfying about seeing a brother pull a broken stuf

@600rrgraham 6 лет назад

Love that trick man. I’ve used t countless times and I’m now deemed the broken bolt guy at our shop. I like running mine on the hot side. Usually build a small nub up then burn the nut on afterwords

@timcollard5690 5 лет назад

I guess I'm not to old to learn. I didn't know this procedure. Good job and Thanks

@billynicgorski1 3 года назад

My Man!!!! I cant thank you enough for sharing this ... saved me a ton of time and money... Great Job .. All the best Billy

@jeffreycanfora1091 3 года назад

I can’t believe it! Big thumbs up! I’m working on that Ford 4.0 sohc and Makuloco... 10 stars bro! First walking me through the timing process, and while I’m in the gasket, carbon build up clean up process, and just finishing valve seal replacement... I figured I’d see about removing the 2 broken exhaust manifold studs so I can be completely done with this right side head. I couldn’t believe it when this video popped up in my ‘tool’ search. Frickin’ Perfect! I’m a union ironworker local 433, welder. Your welds passed this test lol all that matters right. Now I gotta see if I can get this to work for me. Big thumbs up on all videos I’ve need thus far. Thank you.

@kummerow391 6 лет назад

Dude!!!! I can't thank you enough for showing me this!!! I would buy you a cold beer right fucking now if you were here. You literly saved me hours and hours of work!! Thank you soooooo much!!!

@theadmiral5425 6 лет назад

I also use this method...Another tip is while the bolt is cooling down(not red) add a little bit of beeswax as close as you can to the threads. It'll draw right in and make it easier to get the bolt out without turning back and forth as much. Use caution as beeswax is flamable though!!!

@DK-vx1zc 6 лет назад

Thanks for another great informative video! I really appreciate all your videos. I can imagine they take quite a bit of time to produce. Your shop is fantastic.. Like an operating room. Dan

@Vintageguy73 6 лет назад

Have you tried the broken bolt welding rods? They work great especially when the bolt is broken below the surface. Nice work!

@JT-un7dc 4 года назад

Never heard of them. Where can you purchase them? Meaning, what kinda store are they sold at.

@ortiztony67 5 лет назад

Thank you very much and God bless you for the time you take to share this very helpful trick

@hooklinetinker9680 4 года назад

Great tutorial, Brian... Thank you! Really hoping I don't break any studs when I tackle replacing the cracked driver-side exhaust manifold on my 2006 Mark LT. If I do I know this instructional video will be helpful.

@MastersonsCarCare 6 лет назад

Simply amazing repair. Excellent job.

@amr-50 5 лет назад

The Best video on removing broken studs really thankful

@dhh488 4 года назад

South Main Auto Repair has a better one.

@ceasar3696 5 лет назад

Great video! Thanks I have a broken bolt on my truck exhaust. I think I will try this first. Looks easier than drilling or extracting.

@Chris-Fennimore 6 лет назад

Yep, I like this method for removing broken bolts/studs. Good tip. But instead of welding the nut onto the Bolt , I first weld on a washer. It is narrower, so it is a little easier to get the welding wire down to the broken bolt. Once the washer is welded on firmly, I weld a scrap nut onto the outside of the washer.

@lukemartin7029 6 лет назад

Good idea.

@weldingjunkie 5 лет назад

So you don’t weld right into the middle? What do you mean by outside the washer

@DENicholsAutoBravado 5 лет назад

@@weldingjunkie I've wondered that since he said this, but he has notifications off or didn't see it. I thought about his washer, but I couldn't imagine how it was helpful. I could see how the nut would weld with even less contact unless maybe it sat inside the bolt?

@weldingjunkie 5 лет назад

DE Nichols yeah doesn’t make sense to me at all either. Just went the middle lol

@glenblair4103 5 лет назад

@@weldingjunkie I believe by the "outside" of the washer, he means the side of the washer facing away from the engine...however, I could be wrong, it's happened before.

@nickwilkowske8185 3 года назад

This video and your video on removing broken studs was invaluable! Hope I can buy you a beer someday. You saved me a ton of $$

@izcoronel 5 лет назад

outstanding job for a novice more power to you man learn a lot from your channel

@hawaiianf1504 6 лет назад

Thx Dude. Great work there. Thanks for the tips and tricks too. Very Helpful.

@WilliamGreenlee 6 лет назад

Wow look at how perfect the threads were on that bolt! I can’t believe these still break. Great video, keep up the good work.

@FordTechMakuloco 6 лет назад

Yeah its the water and salt trapped behind the nut inside the manifold flange that does it.

@bubba.watercraftj7269 4 года назад

“Rust Jacking” is how I have referred to that scenario. The rust caused metal to expand and snapped fasteners off.

@darwindropmazda 6 лет назад

You got the job done Brian! That’s all that matters💯

@jakeandrus690 6 лет назад

Looks like a great skill to have, thanks for sharing

@dirtyford633 3 года назад

I'm lucky enough to weld fairly well, and TIG weld. I've used my welder so many times to extract studs/bolts I lost count. I think over half of my 7.3 exhaust studs required welding on a nut. Invaluable tool to have in your arsenal.

@ScannerDanner 6 лет назад

Nice job brother. You the man. Hope I don't have to do this on my 8.3 Cummins engine. I'm about to start on the exhaust manifold today lol.

@FordTechMakuloco 6 лет назад

Nightmare!! Good luck buddy!

@MrCharlievan 6 лет назад

Thanks Brian very helpful video good job.

@petemoss9693 6 лет назад

Good job Brian - - -I have done this many times over - drilling then using a easy out ( extractor ) is not the way to go because the easy out tap will break off as you know your self by using them . Good video .

@Chris-eh3du 6 лет назад

Good Job! Great looking shop!

@IDontAShitGive 5 лет назад

Can I do this with a stuck stud sub flush in a cast iron block? Very helpful video thank you.

@andreblanchard9786 2 года назад

Always easier to work on an engine that’s out of the vehicle. But none the less excellent advice to give out there to everybody. Kudos for taking the time to share!

@FordTechMakuloco 2 года назад

Easier for demonstration purposes but when the engine is in the vehicle is is not too bad I do them all the time.

@isaacparsons6486 6 лет назад

This tip works everytime! Especially on aluminum heads

@jimhendrix7776 3 года назад

Shouldnt one be scared of melting the aluminum? Im very ignorant so honest question lol

@prmcollin 2 года назад

Working mainly with wood for a long time, the adhesion strength of welding steel is so nice to deal with. It’s a miracle of science.

@steveham2427 3 года назад

Thank you brain this tip saved me tons of work! God bless you!

@garymitchell2558 6 лет назад

Another good educational video keep up the great work

@1keykneedeep 6 лет назад

Awesome tip and outcome. Looks like a piece of cake

@MeadowsJames 6 лет назад

Thank you for posting this. There is a technique I use to keep from twisting off rusted bolts, nuts and studs. If I suspect a fastener is really stuck from it's appearance or it's refusal to turn with a reasonable force from a wrench, I first use a penetrating fluid. After that, I use a 3/8 drive air wrench or even a butterfly air wrench with Metrinch sockets if there is room, and the air pressure turned down at first. The rapid chattering has loosened many fasteners for me over the years, preventing further welding, drilling, using EZ Outs, re-threading or whatever. When there are no rubber seals, explosives or other fire hazards nearby, I heat the surrounding area if needed with a small torch, or a acetylene torch for big stuff, but not to the point of heating the stuck fastener itself because it will also expand. This expands the steel, aluminum or cast iron away from the stuck fastener. Although the expansion may be only one thousandth of a inch or less, it's enough to free it. But it's really aggravating when fasteners are literally rusted away or twisted off flush. Again, thanks for sharing this video.

@markgarland7202 3 года назад

Great Job !! I`m getting ready to do this on a 1994 f150 5.0 GREAT TIPS !!!

@oby-1607 6 лет назад

Excellent tip. Would it help as you are working out the stud to hit it with something like PB Blaster to help solvent the corrosion that caused this?

@kevin173490 4 года назад

Good video. One skill I don’t have yet is welding. On my bucket list.

@alexpuls8219 6 лет назад

I've had to do this a couple of times at my ford dealership for some of the techs. It works pretty well. Did it on a 2008 4.6L explorer and a 2016 transit with a 3.5 eco boost. Worked both times.

@cookerbullock 5 лет назад

Thanks for the tip.. worked like a champ.

@markk3652 6 лет назад

Is there nothing you can't do?!! Fine job Brian, shop looks great, and sharp new uniform shirts!

@FordTechMakuloco 6 лет назад

Nope it's just a welding jacket lol.

@user-hf5cf9ie1u 10 месяцев назад

Not so easy when motor is in truck😢

@MrJamminguitar Месяц назад

Lol! Yep!!!

@scottweatherman3266 4 года назад

Very excellent. I learned something new. Now, my question. Is the Ford bolts anything like the ones used in the 1987-1994 aluminum heads. GM charges a very high price for the bolts and nuts but, work very well. Thanks for the video.

@ultranitro437 5 лет назад

Great video! I just got ripped off from a shop who failed to remove one of the manifold bolts on my 2000 ford explorer 5.0. I need to get another small welder to try this method.

@garyr7027 4 года назад

Nice trick, I'll remember this when i do my 97 f150. A few of em are nearly gone, look like rivites, so this method might be my only choice. It would be my guess, the heat from the weld is actually aiding in the stud removal process, so you get a two for one solution here.

@tonydmm26y0 4 года назад

Brilliant video, thx for sharing!

@dimitrisgia 6 лет назад

Excellent video! Thanks much!

@traintools585 4 года назад

Thanks for the video. Have to change an exhaust manifold on my 01 F150 and now I'm not as worried about breaking off studs. Would have been worried that the heat would hurt the aluminum, but now I know better.

@justinaulgur9812 4 года назад

How did it go?

@NIghthorseGrows 3 года назад

Currently trying this on my 01 expedition I got on a great deal. 1 of three out today. Was really having a penetration issue. I think I'm gonna try the bigger nuts and build up the nubs a bit. I will fix this thing.

@SIK9D1 4 года назад

Just removed a broken stud out of my 2000 4.6L Thanks for the tips

@galbedxasan2052 6 лет назад

Great vedio thnks we need more!

@Mrdubomb 5 лет назад

Welding right to the broken stud works too, a local machine shop that does these regularly told me that the first two to three threads are always the ones that seize, if you grind down one eighth, they'll unwind every time.

@goneballistic Год назад

This is extremely helpful, great video!

@1slipery42 5 лет назад

did both manifolds on 98 expedition 4.6. cut studs flush with manifold then removed. (I had access to air arc to cut in to pieces) then heated studs red not manifold twice allowing to cool in between, then used 3 jaws stud remover pushed against block to prevent angle twisting. All 16 came out easy 1-2 minutes each. Big thing is breaking rust bond by heating twice (expand /contract)

@ThePlowGuys 6 лет назад

Excellent job.

@derekstarkjr5128 6 лет назад

Ford T. Great Video. My 45 years taught me to put strip of duct tape down whole cylinder head,who cares if it melts ,then put a button of weld right on center of stud,build up if needed,then use needle vise grips,if that dont work ,then you have a shaft to slide nut over then weld nut as last attempt . Waist of wire good 1. I.M.O.

@trappistachel 3 года назад

Can you repeat this in English please?

@curtishouze1471 4 года назад

Loved the video, thank you!!!

@marcuviusblack5781 4 года назад

What a great hack. Thank you.

@nickjaxe 5 лет назад

Nice job...going to remember that one.

@brianhoefer7148 10 месяцев назад

I recently removed a broken #6-32 tap from new aluminum, broke at about 1/2" deep, by tig welding a 3/16" tall spire with .045" tig filler rod, then took a 4" length of 3/32 tig rod and bent a half inch long 90deg at the end and welded it to the spire. Twisted right out. Smallest tap I have ever removed in my 53 years.

@brentgoodkey3067 2 года назад

great tutorial got do just that on my bike stud is about quarter exterior but figure do they seize good works in my day all had was clymer manual for my sled or what can not say more here in north ontario where few specalties here

@KudosBlaine 2 месяца назад

Appreciate this video! Going to try this tomorrow...

@jamesknox955 5 лет назад

Good looking out, Thank you

@dirtydoug181 5 лет назад

That technique saved lots of time in rusty south Jersey

@ScottRods 3 года назад

Excellent video, thanks.

@apachebill 3 месяца назад

Man I appreciate this. I've got to remove a broken stud right behind the passenger turbo on a 15 F150 in the morning. Having to replace all the turbo coolant fittings. I'm no welder but I feel fairly confident I can do this. Then, maybe I can wrap this miserable job up.

@barrybebenek8691 2 года назад

This vid is PERFECT for me. So glad You made this. I’m no welder either but have to do this on my hemi 5.7 (like everyone else). My question is: when I flux-core the nut on, do I need to remove the battery terminals or can I just leave them alone? Thanks. 🇨🇦

@ericsandrin8123 Год назад

always remove cables while welding ANYWHERE on a vehicle...both cables is better...if a welding current can find its way to computer parts because of a bad ground..and there are lots of possibilities and tie the cables away from the posts so they cant find their way back there.....the damage can be anywhere you never imagined..even grounding the welding cables directly to the motor doesnt guarantee the battery will be safe

@amtpdb1 6 лет назад

Do you disconnect the battery and computer before welding? I have heard in the past there could be an issue. What is your take on it? Thanks for the video.

@jimmyjimmyb5416 2 года назад

Great job, good lesson, Thank you.

@cpayne5 3 года назад

I had never welded before, but I recently took a crack at this. My 4Runner had 7 (of 12) broken/stuck exhaust studs. I bought an Eastwood welder, loaded it with a spool of flux wire, practiced for about five minutes on some scrap metal, and then went to town on the exhaust studs. I wasted about 10 nuts on the first stud, but I eventually got it out. The second nut spun out on the first try. I have to buy some more nuts before I go after the remaining studs, but I feel that I'm on my way. In these comments, I read about people warning of welding coated steel, so what I did was soak deez nutz in some vinegar overnight. This dissolves the coating, leaving you with bare steel. Works well, though be warned that rust sets up in minutes, if you don't protect them (WD40 works well for this) after taking them out of the vinegar.

@bryanhenderson8413 6 лет назад

Brian, is this the only solution if you can't get it to work with heat and extractor like you explained in your previous video? I've got one stud on a 5.4 that is stuck extremely hard. #2 "Grab It" extractor just strips.

@jimgam730 4 года назад

Hey, in this situation the weld doesn't have to look good, it just has to hold. And your's did. Good job

@cobraninetysix3883 6 лет назад

Great video! Gives me a reason to run down to harbor freight to buy one of there cheapos to play with. If I can get half way decent with it, and use it more then once in a while, I'll buy a real one!

@rdp2370 3 года назад

Brian, do you put any type of anti seize on the studs at all when reassembling?

@bob14219 5 лет назад

nice video - do you have any tips and tricks for removing broken bolts from ford 6.0 driver side exhaust manifold to turbo up pipe flange ?......the bolts are broken flush and 10mm head is on the far side of the flange...…..cant heat and pound out because of the fragile bellows upstream to turbo......I heated cherry red and tried 10mm wrench on bolt head - wont move....wish I had a plasma cutter but don't....what can I do other than remove up pipe and then torture myself with alignment with turbo issues upon reinstallation ?