Rounded exhaust nuts on manifold

[m1tch]

Hi all,

Just in the process of trying to get the spare engine apart, looks like the exhaust nuts on the manifold aren't playing ball and are basically stuck, I have managed to get 1 nut with stud out the head but the rest aren't budging and are starting to round.

What is the usual method of removal on the MR2 - have noticed that there is a lip around the edge of the exhaust manifold which doesn't seem to be helping matters, guessing others have used a hammer and flattened these out to get better access?

[Carolyn]

Soak with plus gas and keep soaking for several days.  Doing just one at a time, apply heat with a plumber's torch.  Use a six pointed socket (with impact wrench if you have one).  Usually, the studs will come out before the nuts come off.
Never had to hammer on the flange, which seems a very desperate measure as there is a real risk of damaging the ally head.

[Joesson]

As Carolyn says, I made the mistake of using a multipoint socket that nicely rounded of my manifold nuts, use only a six point socket to reduce chance of damage.
You may have some success with Irwin, or similar, nut removers.

[Essex2Visuvesi]

As Carolyn says, I made the mistake of using a multipoint socket that nicely rounded of my manifold nuts, use only a six point socket to reduce chance of damage.
You may have some success with Irwin, or similar, nut removers.

Used Irwins on mine along with some "secret sauce"*








*a 50/50 mix of automatic transmission fluid & diesel

[The Other Stu]

I'm glad you lot got them off.
I had to grind mine off.

I don't really care that much as I wasn't going to replace it, but it's jolly annoying and untidy, particularly as I'd like to bling my engine bay at some stage.

[Carolyn]

I had a few exhaust studs that I'd removed, with nuts still on.  I put them in some JP1 kerosene for a few days.  They came apart with just fingers...

[Essex2Visuvesi]

I went with some high quality stainless studs with Aerotight fasteners
 m http://www.ebay.co.uk/itm/AEROTIGHT-ALL ... gGZKWiabYA m

[m1tch]

I have been soaking the bolts for about a week so far with no luck, might get some of those rounded nut sockets or indeed a splitter, will be changing to copper nuts on the exhaust manifold moving forward, just want to get this exhaust manifold off so I can take the head off!

[maybeturbo]

If they're all really accessible and the engines out you can try this.... clean it all up, put a big nut over the little nut then put a bit of weld round it to join the two then whilst still hot undo it. If youve got or can borrow a welder.

[Gaz mr-s]

I had a few exhaust studs that I'd removed, with nuts still on.  I put them in some JP1 kerosene for a few days.  They came apart with just fingers...

I'm thinking 'how many folk have that lying about...?'

Dragster fuel?

[Essex2Visuvesi]

I had a few exhaust studs that I'd removed, with nuts still on.  I put them in some JP1 kerosene for a few days.  They came apart with just fingers...

I'm thinking 'how many folk have that lying about...?'

Dragster fuel?

I have some!

[Gaz mr-s]

I had a few exhaust studs that I'd removed, with nuts still on.  I put them in some JP1 kerosene for a few days.  They came apart with just fingers...

I'm thinking 'how many folk have that lying about...?'

Dragster fuel?

I have some!

Bloody show-off!      s:roll: :roll: s:roll:    s:lol: :lol: s:lol:

[Carolyn]

I had a few exhaust studs that I'd removed, with nuts still on.  I put them in some JP1 kerosene for a few days.  They came apart with just fingers...

I'm thinking 'how many folk have that lying about...?'

Dragster fuel?

Rocket fuel in fact....

Mitch:  have you tried a torch on them?

[Gaz mr-s]

I had a few exhaust studs that I'd removed, with nuts still on.  I put them in some JP1 kerosene for a few days.  They came apart with just fingers...

I'm thinking 'how many folk have that lying about...?'

Dragster fuel?

Rocket fuel in fact....

Mitch:  have you tried a torch on them?

Rocket Fuel.    s8) s8)     So how easy is to get hold of that?  Does it dissolve rust?

I'm interested to hear Mitch's response to heat.....I will be changing my manifold sometime.

[Essex2Visuvesi]

I'm thinking 'how many folk have that lying about...?'

Dragster fuel?

I have some!

Bloody show-off!      s:roll: :roll: s:roll:    s:lol: :lol: s:lol:

Only have it as I have a model turbine
like this:-

to fit in this

[Gaz mr-s]

 s:bowdown: :bowdown: s:bowdown:  Cool!

[m1tch]

Not tried heat yet as I don't have a blowtorch, I have however bought some rounded nut sockets to see if I can remove them that way as they have basically disintegrated and rounded, other thought was to use a stud remover as the manifold nuts are quite inset and its hard to get a socket in there properly owing to the lip around the edge.

[Call the midlife!]

If you can sacrifice the stud consider cutting a notch in it and using a decent flat blade screwdriver with a lot of pressure, I did it with mine.


Sent from my iPhone using Tapatalk

[m1tch]

If you can sacrifice the stud consider cutting a notch in it and using a decent flat blade screwdriver with a lot of pressure, I did it with mine.


Sent from my iPhone using Tapatalk

Good shout, I was thinking about also trying to get 2 extra nuts on the stud and use them to remove the stud but the thread isn't quite long enough - will see how it goes with the nut removal tool, good news is that the 2 bolts holding the manifold to the main block came off ok - could remove the head with the manifold attached!

[m1tch]

Manifold is now off, I used the below product off ebay, does the job flawlessly, converts to a 17mm hex meaning you can fit a breaker bar easily onto it with a small extension to get through the pipework, so easy! I think its taken 3 of the studs out but that's fine as they came out perfectly. I am pretty sure this engine hasn't ever been apart so will be interested to see what the internals are like in terms of piston oil control rings!

 m http://www.ebay.co.uk/itm/VOCHE-10PC-GR ... 2749.l2649 m