snapped manifold to downpipe stud.

[Jizmondo Scrotmondo]

Removed the head off my Mk2 8v GTI last week and as there was plenty of room, we removed it with the manifolds attached. EVERYTHING came off easily except one of the six downpipe to manifold nuts. The stud has snapped off. Questions are -

Could I just leave it with 5 (I doubt this as there's 6 for a reason)

How do I get it out?

The head/manifolds are on the dining room table

[93fxdl]

The options are,
If any stud above surface, work loose with vice grips and plenty of penetrating oil.
Weld a nut onto stub and work loose.
If broken off flush, you are going to have to dill it out.
First take manifold off head or wrap head in a bag to prevent swarf damaging it, start with a small drill and work up either until you can use a easy out or the stud is weak enough to pick the bits out of the hole. But be aware getting out broken studs and bolts can be a black art to some. And I shall be performing the ritual on a scimitar manifold soon
Ttfn Glenn

[Jizmondo Scrotmondo]

It is indeed a black art. The only thing in my favour is that it's off the car.
I haven't got access to a welder.
There's about 20mm snapped off so there's plenty sticking out.
I don't want to try and take the manifold off as it could be a whole new world of curse word.

pentrating fluid and vice grips I think. If not, I'm hacksawing it off and drilling it out. I'll try some heat. If it goes like it usually does for me, It'll be the hacksaw and drill!

[sal]

I had exactly this problem on my cavalier a couple of weeks ago and tried to weld a nut on and just couldn't get enough of a grip on it. Ended up by drilling in with a small drill and working up til the threads were weak enough to run a tap through and fortunately I got it sorted.

If you can get vice grips on I'd try to use them before drilling. Bang the middle of the stud with a centre punch to shock the threads loose and let the penetrating fluid in.

Hope you get it sorted mate.

[93fxdl]

Don't try to unscrew it straight out, work it back and forth to work it loose and as said before give it some hammer time to shock it free
Ttfn Glenn

[RobinJI]

Had the same issue on the Golf GTI manifold I fitted to the Scirocco. I welded a nut onto the remaining stud (screwed right down on so the top of the stud was flush with the nut, loads of weld on a decent heat) it just snapped it off flush with the manifold.

I bolted it on with 5 of the 6 and a new gasket and it was fine for the remainder of the time that engine stayed in the car. (Over a year and ~20k)

[bl1300]

I have done the same with mine but unfortunatly mine has snapped off below the surface. I have been soaking it in penertrating oil for a couple of days and then will be attacking it with a left handed drill bit, these are good as sometimes they cause it to just turn out as you drill. Its also the perfect excuse to fit a new stainless tubular manifold ive been hankering after.

[damageandy]

if theres that much stickin out and you havnt got a welder, id try nd stick the rest of the stud in a vice, they get soem heat into the surrounding area and then work it loose.

or just find someone with a welder, thats always the esiest way to get them out.

in reality alsong as the gasket is ok, it will more than likly be fin with just 5 in it, lost count of number of cars with snapped studs and they rarely leak.

[Jizmondo Scrotmondo]

I've started saoking it in penetrating fluid and try and get some vice grips on it to work it free. If not, I'll go with the five. Once again, thanks for the replies!

o x o X is which stud has snapped so I reckon it should be OK with 5.
o o o

[nelliem]

I've had some success drilling into the stud then tapping a torx bit into the hole and using a ratchet to undo it. Drill bit and torx bit size depend on the size of the stud and what you have that are a close match.