I've been there, done this on my 9-5 Aero. The studs on the 9-5 are M8x1.25 pitch; I'd wager that the 2.3 9k bolts are the same spec. I'd second the vote for better-quality studs if you can get a hold of them easily enough.

I had the top bottom right hand studs break on my 9-5 (#4 cylinder). Eventually the exhaust leak sounded pretty trashy and it trashed the exhaust manifold gasket.

If you're lucky to be able to drill (carefully!) into the broken stud straight and get an EZ-out in, you'll be quite fortunate.

Otherwise, figure on drilling out the remnants of the bolt (again, try for a straight drilling, squarely on the remannts, in the off-chance you can extract the remnants of the stud out of the hole without having to booger up the original threads. If that doesn't work, a heli-coil type insert is your next option. Some kits come complete with extra coil inserts, the insert tool and the appropriate tap to cut new threads (for an 8mm helicoil, use a 10mm tap).

The tool that really helped me in lieu of a right-angle drill is a right-angle adapter for a standard drill (available at Sears), which will it easier to get a square-on hole drilled.

In any case, have fun, be patient and good luck!

Paul
'01 9-5 Aero, 230k miles
'86 9000T

posted by 65.100.23...

• Stripped Exhaust Stud Hole, AeroAndy, Sun, 19 Apr 2009 20:57:30
  • Re: Stripped Exhaust Stud Hole, Paul E, Tue, 21 Apr 2009 19:45:25 <-- Viewing This Message
    • the stud is not broken off - just threads stripped, oldsaab, Tue, 21 Apr 2009 21:18:23
  • Broken studs., Montana Tom , Tue, 21 Apr 2009 12:09:04
  • To answer your question about running it minus a stud, turrbo , Mon, 20 Apr 2009 19:57:06
  • Exhaust studs always make me wonder why, Noel, Mon, 20 Apr 2009 06:09:11
  • Not standard exhaust studs, Bill Homer , Mon, 20 Apr 2009 05:50:59
    • sure you're not confusing e-torx and twelvepoint? nm, Simon S, Wed, 22 Apr 2009 12:57:38
    • Re: Not standard exhaust studs, I agree..., Street, Mon, 20 Apr 2009 11:54:48
  • Re: Stripped Exhaust Stud Hole, Bill Davies, Mon, 20 Apr 2009 03:05:37
    • Re: Stripped Exhaust Stud Hole, AeroAndy, Mon, 20 Apr 2009 07:40:00
      • Re: Stripped Exhaust Stud Hole, DickT , Mon, 20 Apr 2009 08:10:54
        • Meant to say one missing n/m, DickT , Mon, 20 Apr 2009 11:50:38
      • Re: Stripped Exhaust Stud Hole, oldsaab, Mon, 20 Apr 2009 07:54:59
        • Re: Stripped Exhaust Stud Hole, AeroAndy, Mon, 20 Apr 2009 11:54:05
          • You should be able to do this in situ., Gene N , Mon, 20 Apr 2009 13:32:51
          • Re: Stripped Exhaust Stud Hole, jdlincoln , Mon, 20 Apr 2009 13:27:32

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