Exhaust manifold studs

[RS MN]

so i'm going to be buying some headers, and i was wondering how often people break exhaust manifold studs due to rust or seizing of the bolts?

would it be a smart idea to buy myself a new set of exhaust mani studs? or is it something not to worry about much? any tips for getting the stock mani off without busting studs?

thanks!

[TEK]

i say if your gonna do it your self spray the studs down with pb blaster or some sort of penetrant

[RS MN]

that was my plan anyways, im just not wanting to break stuff without having some sort of "fix-it" plan.

[TEK]

yea when i was looking at mine the other day they didnt look like they would break when removed but if they do just get a tap set and drill them out its not hard to do just time consuming just let the spray sit over night

[RS MN]

thats my plan, im just trying to figure out if they are very susceptible to breakage or not so i know if im going to need new studs or not. i hear the biggest issue is pulling the thread out of the heads themselves, which i can easily fix.

[SportyMark]

more often I fine the nut is seized on the stud and when you go to get them off the entire stud comes out of the block. In the several years I have been specialized on Subaru I have only broken one exhaust stud.

[bigjoshsubyfan]

I've had mine on and off several times and I have had one that the threads gave up on me. Easy fix though.

[MrToad]

PB Blaster, heat, and a low torque impact will help. New studs are a good idea if the there's significant rust on the threads. Helicoils for rescue. A drill guide made of steel and secured to the head by the surviving studs will help keep you from wandering into the softer aluminum if you have to drill out a broken stud. Good luck.
JT