[Turbo Terror]

hey guys, i got a buddy that has a 98 mustang cobra 4.6 5 speed
his passenger side ex. manifold has a broken stud in ot where it meets the ex. pipe, he wants to ask the experts how to get it out, thanks in advance

TURBO

[RCastle]

Spray it with a penetrant like P.B Blaster,spray all the others too if they are still attached.Drop the exhaust,allow it to sit overnight if you can.Then take vice grips and tighten down on the remaining stud and work it out. I f you are in a shop and ahve access to a oxy/aceteylene torch,heat the manifold flange around where the stud is,metal expands with heat,then use the vice grips to remove the stud. If not use P.B Blaster over WD-40,much better penetrant lube.

[Mr Ed]

its not easy with the manifold on the engine and in the car but you could try;
put two or three nuts on the stud and lock them altogether with spanners then put a spanner on the lowest nut(closest to the manifold itself) and try to unscrew the whole thing
-heat it up with a butane torch and try vice grips
-grind it off flush with the manifold then starting with a small drill, drill a hole through it and slowly increase the size of the drill bits
-grind it off flush with manifold and drill a suitable sized hole in it and use an 'Eazyout' which is a broken stud/bolt removing device that looks like a thread tap and screws in an anticlockwise direction (avaialble at engineering shops).

You would do the same as above if you take the manifold off and did it on the bench.
Also pay to soak it in a lubricant like CRC/WD40 overnight prior to attempt

[RCastle]

Any grinding or drilling you may do,WEAR SAFETY GLASSES. Especially if you do it on the car instead of removing the manifold.

[Old School Nut]

Originally posted by RCastle
Any grinding or drilling you may do,WEAR SAFETY GLASSES. Especially if you do it on the car instead of removing the manifold.

yup, dont forget that! also about working it out, I have found that loosening then turning it back in, then loosening, then turning it back in and spraying oil in the mean time works well. good luck!