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VP
Dodge Dakota
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10/24/2002
12:44:53
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 Subject: Exhaust Manifold Studs
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I have a 97 3.9 V6 and this weekend I'm going to have to replace the exhaust manifold studs on the passenger side (2 of them are broke off in the head)and just wanted to know the best way to get the old ones out and what size to put back in?
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jkw
Dodge Dakota
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10/24/2002
13:11:30
|  RE: Exhaust Manifold Studs
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This must be a common problem. On my 94, both sides have 2 that are broke off in the head. I'd be interested in hearing any suggestions also.
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Pistolero
Dodge Dakota
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10/25/2002
00:40:12
| RE: Exhaust Manifold Studs
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I've read several posts in past months from other folks who've had to deal with this problem. They've pretty much all ended up having to drill them out. One guy even removed a fender liner so he could get a good enough line on the stud.
Besides hopefully adding to the other mods that I have in store for my truck, this was one reason that I installed headers. I haven't heard of any problems with broken header bolts.
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Larry B
Dodge Dakota
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10/25/2002
02:07:40
| RE: Exhaust Manifold Studs
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Message:
Mine broke off too on my 95. Bought a drill from Sears for tight places like that. $140, but I wanted it anyway. An adapter that lets you drill at 90 degrees would work too. You have to take the manifold off and drill holes in the broken off studs. Being real careful to get as close to the center as possible. Then I tapped in screw extracters and tried to back them out. One was real easy, the other wouldn't come out. Even after soaking it with penetrating oil. Wound up drilling it with a drill bit just a little smaller than the hole and retapping it. 5/16" tap I think. Just take one of the other bolts or studs out and match it up. I used Grade 8 bolts to replace the studs. It'll take a lot to break them. There are no manifold gaskets on my truck. It's just metal to metal. That's why they broke off.
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