Well after hours of trying to get the last bolt out of the exhaust manifold, I was able to cut it out with like 20 dremel bits. SO now I am left with 3 of the 4 studs still in the manifold with no heads. How do I get them out?

 

drill them out

 

Best way to do this? I've never had to do it before...

 

Is the turbo off now? with studs sticking out of it?

 

Yes exhaust side is out, studs are sticking out of the manifold.

 

oh, well you need to drill the bolts on a drill press very carefully, make sure to go right in the middle, and straight up and down (which is why you need the drill press, and not just a hand drill)
Then use an extractor to pull them out, an extractor looks like this in case you dont know

 

Manifold is still on the head though

 

Don't do that, you have an incredibly high likelyhood of snapping the easy-out, and it's carbide, nothing short d dynamite will be able to get through it at that point. Use some brand new vice grips with incredibly nice(grippy) jaws, tighten the living **** out of them, and after soaking all studs in as much penatrating oil as possible, SLOWLY back them out. Do NOT try this with 20 minutes of daylight after do dinner, give yourself some time, you don't want to **** it up.

 

PB Blaster soaking plus vise grips got all 3 out


Now I'm trying to put the new ones in, 3 with allen heads, hard to get in there... gah

 

You're welcome.

Like I said, everything but the rear drivers side should be EASILY accessable with a ball end Allen wrench, the ~6" kind. Are you sure you have the right bolts, and did you chase the threads with a tap first? Make sure they go in easily without the turbo before you try to bolt it all up.

 

Just went and got tap/die set from Harbor Freight. Also got ratcheting wrench, ball head bit for socket wrench and other ****. All for $30


HF FTW

 

Hopefully that large ball end allen socket will fit in there. That's much bulkier than the 6mm thick wrench I use.

 

Oh no I also bought standard L shaped ball set last week.

 

Well I got everythign back in, upon tightening the SS allen head bolt to manifold (top left from side of car) I stripped out the head when tourqing it down, so when I have to take it all back out I have to worry about that. BUT everything is good now, NO LEAKS. WOOT

 

Good job, don't tighten them that much. Hold it as straight as possible, and get it just a fair amount past snug, no more.

 

This will help you get the bolt out:

I always welded nuts onto broken studs to get them out.

 

I got the bolts out so everything is in. But created a new problem when I stripped the inside of the allen. Guess I don't have to worry about it till i swap the hot stuff.

 

How do you guys tighten the bottom 10mm nut on DP that bolts to the Greddy TDO4 turbo. I have the Racing mazda fat DP.
I got the nut started as I started others which are bolts not studs but can't get a 10mm wrench on the one nut...
I have open end and boxed ends and sockets that of course won't fit.

Thanks

 

Wow this sounds horrible. Vband should be mandatory for the universe

 

V bands are nice but not right this minute....