4.6L (1996-2004 Modular) Mustang Technical discussions on 1996-2004 4.6 Liter Modular Motors (2V and 4V) within.

Snapped a header stud! ****

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Old Apr 25, 2008 | 06:38 PM
  #1  
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4.698GT
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From: Port Monmouth, New Jersey
Default Snapped a header stud! ****

So I snapped a stud that connects the h pipe to the header. It broke flush at the header. I tried an screw extractor set to no success. My father suggested drilling and tapping the header and using a bolt and washer set up on it. Anyone else have any suggestions. im pretty bummed this happened.
Old Apr 25, 2008 | 07:13 PM
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Default RE: Snapped a header stud! ****

if you have a torch i have had good luck just melting out the stud and then chasing the threads,and installing a new stud.the stud will melt before the cast iron. you will have to do it a little at a time and cool the manifold in between. but you gotta be good with a torch
Old Apr 25, 2008 | 07:19 PM
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4.698GT
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Default RE: Snapped a header stud! ****

Its not the cast iron manifold its a bbk ceramic coated header. I believe they are stainless steel.
Old Apr 25, 2008 | 07:26 PM
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Default RE: Snapped a header stud! ****

ur gonna have to drill
Old Apr 25, 2008 | 07:57 PM
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Default RE: Snapped a header stud! ****

i just had to do the same thing. get a torch and grinder, a drill wont do much but break bits on that stainless. cut a notch into the side of the flange up to the stud with the grinder. then use the torch to melt the stud out. some of the flange will go too, but use a 3/8 bolt and you will be ok. put the bolt in from the top of the flange and tack weld it if you can. if not just make sure u can get a wrench on it and you'll be fine. its a pain, but it works. good luck.
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