spooln30 Posted May 20, 2013 Share Posted May 20, 2013 Well last week while sitting at a stop light I thought someone stuck a smoke machine under my hood. NOPE!!!! It was just from the large amount of oil dumping onto my exhaust. I knew the separator plate was leaking as well as my cam seal but the plate cracked so I had to bite the bullet and pull the engine. I was wanting to put this off untill I did my STI drivetrain swap but I like living so I just pulled out the heart. Everything came apart or off easy but then it came to the exhaust manifold nuts and I could see they were going to be a huge issue but not as bad as they've become. First I used a die to clean the rusted threads after the nuts then I sprayed all of them with PB Blaster and let them soak for a hour while continuing to spray them in between. Next I grabbed a 14mm deep socket and ratchet and my Map gas. I don't have a good torch set and if I did I wouldn't be where I am now. So I heated the first one for about 5 mins and it came out but nut and stud together. The next one same deal heated it up but then SNAP, broken stud, then SNAP, SNAP SNAP SNAP. After I broke the second one I heated them up for 10+ mins never getting the nuts cherry red because it's only map gas. I really could've used a torch. Well they all broke about a 1/2" off the head which I though was good but NOPE. The studs are corroded to the aluminum its ridiculous. I am now in the process of drilling out each bolt until I get these PIA POS studs out. Most likely I'll have to heli coil them but at this point I just want to get this done. I just can't believe how corroded the studs are in the aluminum being this car spent 11 years in AZ and really was never driven in a winter until this past one with me. I've never had a Subaru with such fucked up exhaust studs off the head. Huh ok I am done venting now. Back to the BS oh wait back to Home Depot cuz I need some new drill bits. Link to comment Share on other sites More sharing options...
spooln30 Posted May 20, 2013 Author Share Posted May 20, 2013 Oh yeah I did try to remove the studs with my stud extractor socket with heat and when that didn't work I tried a vice grip but the studs wouldn't budge they just rounded off. I even tried to clean the surface and PB blast them again but they are so corroded it was time for drilling. Not how I wanted to spend the weekend and probably Monday and possibly Tuesday. Link to comment Share on other sites More sharing options...
subikid90 Posted May 21, 2013 Share Posted May 21, 2013 I had a similar issue on my roommates car. We welded nuts onto what was left of the stud and they finally came out. Welding the nuts heated them up pretty well. -Subikid90 1997 Legacy GT 5spd & EJ251 w/EJ25D heads ~10.5CR 1998 Legacy GT Limited waiting for EJ22T hybrid swap Link to comment Share on other sites More sharing options...
monkeyposeur Posted May 21, 2013 Share Posted May 21, 2013 Dude that sucks. My exhaust man bolts were also rusted to shit on my 22T but me el cheapo Kawasaki electric impact gun spun them right off. Link to comment Share on other sites More sharing options...
monkeyposeur Posted May 21, 2013 Share Posted May 21, 2013 Dude that sucks. My exhaust mani bolts were also rusted to shit on my 22T but me el cheapo Kawasaki electric impact gun spun them right off. Link to comment Share on other sites More sharing options...
spooln30 Posted May 21, 2013 Author Share Posted May 21, 2013 Yeah today I borrowed my guys torches and the remaining studs I didn't drill out STILL wouldn't come out. Even with the heat of the torches. The two I drilled out it looks like the corrosion worked its way down four threads from the top deeper then I actually thought. Then I ran out of oxygen so the torches are done. LOL. Back to drilling. Sucks. I don't thing welding nuts will work because I tried torches but I have a mig so I'll give it a try. I have three studs to try new options. Link to comment Share on other sites More sharing options...
Zues Marine Posted May 21, 2013 Share Posted May 21, 2013 damn dude i know your frustration right now, i hope you try with a wrench and it pops off somehow, lol Link to comment Share on other sites More sharing options...
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