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Old 06-21-2018, 02:09 PM   #1
chansdaman
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Member#: 457390
Join Date: Oct 2016
Chapter/Region: MAIC
Location: Ellicott City, MD
Vehicle:
2002 WRX
WRB

Default Stripped bolt and stud near downpipe and turbo

So I was down to the very last bolt during a DP replacement, and I ended up stripping the bolt. I tried using a nut splitter, but went overboard and ended up stripping the stud as well. Itís a hot mess. My next plan was to get a dremel try to cut the nut off, then use a stud extractor (see pix). I donít even know if the stud extractor will be able to turn the stud (if I was looking at the stud from the back of the car towards the turbo, does it turn counterclockwise to loosen?)

Any advice on this predicament would be great.
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Old 06-21-2018, 02:56 PM   #2
PVNRT
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Member#: 483821
Join Date: Mar 2018
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2004 WRX 2.0 18g

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If it's your last bolt (stud) you should be able to slip the downpipe off now once you disconnect the other end. If it is too mangled, just cut the stud flush with flange so you can get dp off. There should be enough thread now with downpipe gone to double nut the stud and remove it. Studs are normal "righty-tighty lefty-loosey" so you should be able to double nut it and remove the stud, but you need those healthy threads which are blocked by the flange in photo. If there is not enough thread left to double nut the stud then you will likely need to drill it out, you can try vice grips to remove remaining stud once dp is off but it probably won't be enough and you will need to drill it out.

Exhaust leaks after turbo aren't a big deal if this is your only car you can safely run 4/5 bolts to go run to the store to get a new stud.
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Old 06-21-2018, 03:47 PM   #3
chansdaman
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2002 WRX
WRB

Default

Thanks for bringing some sense into this. I have all new studs and nuts standing by. Will give this a try.
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Old 06-21-2018, 09:46 PM   #4
chansdaman
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2002 WRX
WRB

Default

Thank you PVNRT.
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Old Yesterday, 09:49 AM   #5
PVNRT
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No problem, you can heat wrap the downpipe for about $30 or less while its out. Ebay sells lengths of DEI wrap, I used 3" hose clamps to secure mine. It won't add power its just one of those things that helps nearby electronics live longer.

You probably already know but you are missing cotter pin for wastegate arm.
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