Exhaust Manifold Helicoil Failed - Defender Source
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  #1  
Old October 7th, 2016, 11:44 AM
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Exhaust Manifold Helicoil Failed

I was re-fitting the exhaust manifold and the stud backed out. It looks like the exhaust manifold stud sheared at one point, a helicoil was used to repair it and then the broken stud was reused.

Attached photos of the hole, not great but it doesn't look like there is a sheared stud in there. Also a pic of the stud, the short side was in the head and the end is smooth and ground down, not jagged like it just sheared. Stud also has metal wrapped around it that came out with it.

My plan is to clean up the hole, install a new helicoil and a stud. Solid plan or am I missing something?

Any helicoil kit recommendations or just go with a metric kit off Amazon?

Thanks,
Alex
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  #2  
Old October 7th, 2016, 11:54 AM
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Head bolt or exhaust manifold stud? What are we discussing? What engine?
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  #3  
Old October 7th, 2016, 11:56 AM
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may be the picture but it does not seem it was ever helicoiled..the stud is always short and the shavings suggest a simple stripped thread.
yes a rethread and heli coil should do wonders for your case.
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Old October 7th, 2016, 11:57 AM
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Quote:
Originally Posted by Red90 View Post
Head bolt or exhaust manifold stud? What are we discussing? What engine?
Sorry- exhaust manifold stud. Is my repair plan the right approach? 300tdi
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Old October 7th, 2016, 12:03 PM
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A correct helicoil should be fine assuming it has not already been helicoiled and failed.
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  #6  
Old October 7th, 2016, 12:04 PM
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Quote:
Originally Posted by Red90 View Post
A correct helicoil should be fine assuming it has not already been helicoiled and failed.
Thanks.

And if that is the case?

Will this kit work?
https://www.amazon.com/gp/product/B0...A10PRH2DFOVNA8
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  #7  
Old October 7th, 2016, 12:32 PM
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I much much prefer wurth time-sert over helicoil. You just need clearance to install it and it's pricey
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  #8  
Old October 7th, 2016, 12:52 PM
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if you have a fastenel shop near you they stock heli coils
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  #9  
Old October 7th, 2016, 02:15 PM
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This is what came out with the exhaust stud. It was threaded on the end of the stud. I would think if I had just stripped the thread it wouldn't be a uniform shape like this.
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  #10  
Old October 7th, 2016, 02:18 PM
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Is it steel or aluminum? Check with a magnet.
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  #11  
Old October 7th, 2016, 02:24 PM
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Quote:
Originally Posted by Red90 View Post
Is it steel or aluminum? Check with a magnet.
Steel

Should I get this:https://www.amazon.com/BIG-SERT-Time...9QHBCFY83J11BG

Not sure on what size to get to repair it.
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Old October 7th, 2016, 07:15 PM
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Nope just get the standard time sert not the big sert. Big sert is for areas that are severely damaged or have been drilled out.

I mount my time serts with a high quality thread locker. It also helps to have a tap handle

I've never had one pull out, and I've used them for motorcycle cylinder studs previously
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  #13  
Old October 8th, 2016, 11:38 AM
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Might be time to consider tapping it out to a larger size?
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  #14  
Old October 8th, 2016, 11:06 PM
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Quote:
Originally Posted by leastonce View Post
Might be time to consider tapping it out to a larger size?
Hadn't even considered that. Seems like the easiest option. I understand how to tap it, but what sizes do manifold studs come in? Do I just pick up a new stud at a local auto parts store?

Thanks,
Alex
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  #15  
Old October 8th, 2016, 11:09 PM
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I would figure out the thread pitch and get the next step up.
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  #16  
Old October 8th, 2016, 11:25 PM
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Quote:
Originally Posted by Brewie212 View Post
I would figure out the thread pitch and get the next step up.
I believe it's m10x1.5. What would be the easiest to get locally? Assuming not metric.
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