Broke a stud off the turbine outlet trying to tighten the downpipe after I noticed an 1/8th inch gap between the two. Apparently when I had my clutch done they put the 4 nuts back on, forgot or lost one washer, and left a considerable gap which I finally realized was the source of my exhaust leak. What are my options? Can I drill the stud out or something and replace it or am I out the 200 some dollars it costs for a new one from FM?

 

from doing it a couple times on subaru turbo's, it can easily be fixed.

you could drill out/replace, or weld on/rethread

 

Call FM they gave me a good deal on a new manifold that had two broken studs stuck in it

 

I'm assuming that the stud is broken below the point where you can get something on it to grab it. Therefore, remove turbo, extract broken stud, and upgrade the turbine outlet and manifold to turbo studs to 10mm. Done.
Don't waste money on a new turbine housing.
Before you do though, make sure the downpipe is able to support 10mm studs by either calling FM or making sure that the holes you will drill out won't go into the piping.

 

Unfortunately, there is no room on the turbine housing to put 10 mm studs there. I wish, though.

Send it to us if you like. We can fix it up. Or you might try a local machine or exhaust shop.
Stephanie

 

Actually, I think its got a little, maybe 1/4'' or more, stump sticking out. Think I can ( or shop ) grab on to that, extract it and put a new one in?

 

Easy, Easy. We can get studs out that are in 1/4" or more.

Try soaking it in PB Blaster for awhile. Then (if room) double nut it and back it out. For someone with the equipment, it would be easy enough to weld onto the stud and back it out.

Stephanie

 

Listen to me cause I have done this on my car. Clamp a vise grip on the stud and clamp it down really really hard, take a torch and heat up around where the stud screwed in. Try not to get direct heat on the stud. If the stud turns red, don't turn it or it'll snap. Turn the broken stud out. Game over. Make sure the threads are clean, replace the stud and bolt and you're done.