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Old 07-26-2007, 10:12 AM   #1
kkos06
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Join Date: Oct 2006
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2006 WRX
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Question Bolt snapped off in Manifold...help???

So last night we started to pull my manifold off of my 06 WRX to put in new injectors, rails and plugs and one of the Manifold bolts snapped off and is stuck in the manifold...any suggestions to get it out...tap and die maybe...need some suggestions...oh and by the way some of the other bolts were corroded a little about half way down where the other one snapped off
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Old 07-26-2007, 10:15 AM   #2
rage557
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Join Date: Jun 2006
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2001 Impreza 2.5rs

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The same thing happened to me last night too!!! If you have a welder and there is enough thread left to put on a nut, you would weld the nut on the end of it and try to unscrew the stud from the block. I dont have a welder so i gotta call the dealership
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Old 07-26-2007, 10:33 AM   #3
kkos06
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thats a good suggestion but my manifold is still on and i dont know if i can get it off without getting that out first it is the last thing holding it on so im not sure what to do at this point as it is way down in there
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Old 07-26-2007, 12:08 PM   #4
Metallrulz
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I'm unsure of how Subaru motors are, but I've had this happen on Hondas. Is the "bolt" you broke really a stud (I would think so). If so, by you breaking the head off, it took all the stress off the stud that was being excerted on it, so it should not be very difficult to remove. Then you'd just need to find another stud to replace it with.

If you can fit a drill in there, you'd want to drill a small hole and use an easy-out to back the stud out. Pick up an easy-out kit (get a good one, like Craftsman) and it'll tell you what size hole to drill for each size easy-out.
On my '95 Integra, while I was drilling the stud it actually broke lose and started to spin, so it was cake getting out. I don't see your stud being too difficult to remove considering how new your car is.

You really should not have broke the stud to begin with considering how new your car is. If you have a nut that's stuck again, heat the nut up with heat. That will expand the nut and it will come off the stud relatively easy. If you don't have a Oxy Acetylene torch, then you might get by with a propane torch.

Also, MAKE SURE you put never-seize on your studs before you reinstall your exhaust manifold. It will make it much easier to remove next time.
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Old 07-26-2007, 12:57 PM   #5
kkos06
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thanks for the advice guys im gonna see what i can do when I get out of work...keep your fingers crossed
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