Broken exhaust manifold stud
My wife's Range Rover cracked an exhaust pipe Sunday. The section that broke was between the catalytic converter and the exhaust manifold. Luckily that section unbolts, and the rear part, with the catalyst, came right out. The forward part, bolted to the exhaust manifold, was a little harder. Two nuts came off with lots of penetrant and slow, even pressure. One nut broke its stud so easily that I think some previous mechanic or owner over-torqued it.
So, I've got the unpleasant job of removing the broken stud. I've only got about 1/4 in. of it coming out the bottom of the manifold flange. That's not enough length to screw two nuts to and wind it off. I don't want to saw a slot in the end because then the stud becomes so much weaker, and if I buggar it up then it becomes that much harder to get out. Does anyone have any ideas?
Thanks for any ideas,
Scott
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