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'95 900 SET 5 speed. I had been hearing an odd noise, that was either the turbo or exhaust leaking past the flapping manifold gasket where 2 studs had snapped off.
I figured that the best course of action was to replace the 2 studs first and listen for happy sounds, so here is the story of... THE STUD REPLACEMENT.
First, I borrowed an easy out kit from my brother. It's a complete set of left twist drill bits, graduated tubes and hardened easy-outs.
Step 1 - remove cooling fan. Easy job, though it required disconnecting the hose from the power steering pump (a dribble of fluid on the driveway). I also removed a couple of intake air hoses and the grille.
Step 2 - insert a graduated cylinder into the hole in the manifold (fits nicely) and drill a small hole in the centre of the broken stud. My 18 volt chinese cheapie drill fit nicely between the radiator and the broken stud.
Step 3 - with the small hole drilled in the centre, I then inserted a larger graduated cylinder and drilled a 3/16 hole in the centre of the stud.
Step 4 - Insert the easy out (4 inch non tapered, splined, hardened) and tap it into place.
Step 5 - slide the "nut" onto the splined shaft and back out the stud fragment with your socket wrench.
Remember, these studs have broken due to thermal/stretching stress, not binding in the threaded hole, so getting them out isn't really difficult. Drilling a centred hole is and this kit made it easy.
So, flush out the holes with WD40, apply nev'r seize to the new studs and install them. Snug them up and test drive - THE NOISE IS GONE!
Now that the broken studs have been replaced, I'll probably re and re all the rest, installing new studs so that I don't run the risk of more broken in the near future.
Cheers all and I hope this helps somebody else.
Nielsen
Search terms:
exhaust studs
DIY
posted by 216.75.189...
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