Date: Sun, 15 Jul 2007 10:05:39 -0700
Reply-To: David Kao <dtkao0205@YAHOO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: David Kao <dtkao0205@YAHOO.COM>
Subject: Re: exaust removal woes
In-Reply-To: <d1ea9acf0707150406k4008ae6t37e3bc2c92e9daf3@mail.gmail.com>
Content-Type: text/plain; charset=iso-8859-1
Craig, I'll get to where you need the help straight, broken stud removal.
I had removed, twice, broken exhaust header stud from my V6 Volvo engine.
It's not very hard actually, but you probably need to drop the engine unfortunately.
Dropping a wasserboxer engine is not hard either but it does require some more tools.
I suspect you will have enough tools to do it yourself. But dropping a wasserboxer
is definitely worth the effort if you love your 85 that much and want to keep it
going. You will have to dismantle most of the stuff on the top of the engine. But
it gives you a mandatory sweeping opportunity for checking all the components on the
top of the engine, especially FI fuel lines and the intake system.
To remove a broken exhaust header stud (stuck in the exhaust port of the cylinder head)
You need a handheld drill with 1 or 2 drill bits. It's better to use 2. The first should
be a cobalt drill bit of 1/8" size. Use this drill bit to drill 1/4" deep into the broken
stud in the center of it. Then use a 3/8" cobalt drill bit to drill into the same hole
created by the 1/8" bit about 1/2" deep. Be careful not to drill into the Aluminum
cylinder head. Cobalt drill bit is very powerful in drilling into steel. You should
have no difficulty drilling through the broken stud. Do not use other kind of drill
bits. You will mess up the cylinder head. Cobalt drill bits cost less than $5 each for
the 1/8" and 3/8" sizes and they are available from Home Depot, Wal-Mart, etc.
Once the hole is drilled you can use a stud removing bit, similar to a drill bit
but has a tapered shank made of steel and cheap still. Use a small hammer to tap on
the bit to drive it into the hole you drilled on the stud. Use a wrench to turn the
bit counterclockwise. The broken stud will come out. The broken stud will not refuse
to come out because it is not under any stress when the header is already removed.
It will be a complete relief when you see the broken stud come out and the cylinder
head unharmed whatsoever.
The reason the engine needs to be dropped is so that there is room for the drill to
do the work. Bus Depot should have replacement studs. It's a good online store based
on my purchasing experience from it.
Dropping the engine is beneficial for your future care for your Vanagon. It may be
a little challenging the first time. But I am sure you can make it if you plan ahead
and do it with a big heart.
I am in California. I can't come to help you unfortunately. Good luck.
David
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