Hey I need your help from anyone who has been here before. I was replacing the intake manifold on my B16A when one of the top stud coming out of the block snapped off. Now I cannot tighten the intake manifold properly and will likely have a leak. Even if I don't I still have to get it replaced. HELP! How do I replace that stud? speedshift23@yahoo.com

 

Take it to a machine shop and have them drill it out, either that, or just use a lot of RTV sealant (or HondaBond) around that stud, messy but it works.

 

To do it correctly, you will have to get it out.

Is it snapped off flush w/ the block? if so, you can try to use a stripped screw removal tool, but it prob. won't work.

There's a VW guy on another board I frequent that takes a rusty nut slightly bigger than the stud, sit it on top, fill it w/ metal from a MIG welder so that it fuses to the stud but not the nut, and simply take it off w/ a wrench. Has good results, usually.

If all else fails, take it to a machine shop and have them drill it out till it gets right to the threads, then run a tap through it to clean the threads. It will prob. not be that easy, so you'll need to drill it out a bit more and have it re-tapped to the next biggest size, or put in helicoils.

Argh, my hands are sore.....hope that helps a bit!

 

oh, and if it didn't snap off flush at the block, take two nuts that fit the stud, put them close to the bottom of the stud, and start using the bottom nut to wrench off the stud; the top nut will act as a jamnut, preventing the bottom one from just turning off.

 

Had a problem on the other end that I fixed today. Some bone-head cross-threaded a nut on the stud to the header and snapped it off flush to the head. I had to pull the radiator to be able to fit a drill down low enough to drill it out. Luckily I drilled it perfectly to the end of the stud, and an EZ-out pulled it right out. I was really happy to see that the threads on the block were undamaged. The new stud went right in!

I'd say an EZ-out is your best bet. Make sure to use a center punch in the center of the stud so your drill bit wont walk, after that it should be a piece of cake.

Good luck!