Help me

[zeke]

while driving my 240z I heard a exhaust leak .

I found the leak between the exhaust manifold outlet

and the exhaust pipes .

the problem is that when I tightened it I broke the bolt

is it possible to use a tap and die set or will I need more extensive work done such as a new manifold?

any help is graetly appreciated

thank you

zeke

[skip260z]

you probably won't need to replace the ex. manifold.

But to fix it right, you will have to remove the ex manifold and take it to an exhaust shop or machine shop or decent service station and have them remove, replace the stud.

Have them do all 3, may as well start out with fresh, non-rusty studs. And use new nuts and a gasket.

Hopefully you can re-use your ex manifold gasket, else you will have to pull the intake sides off to replace this "double gasket".

But, that could be a false economy, so maybe you will want to re-new the whole gasket.

Good luck with those manifold studs into the head!

[zeke]

So you dont think I will need to take off the entire manifold

unless I need to change the gasket right?

[skip260z]

Unless you have some extreme capabilities to get at that broken exhaust flange-downpipe stud!

You said:

"I found the leak between the exhaust manifold outlet

and the exhaust pipes .

the problem is that when I tightened it I broke the bolt

is it possible to use a tap and die set or will I need more extensive work done such as a new manifold?"

That tells me that you broke a stud at the flange where the exh manifold joins the downpipe - correct? No biggie, happens all the time.

But you can see from the extreme angles and limited space you have, that there is no forseeable way for an on-car fix. Least not in my view.

So.. suggest that you carefully remove the remaining 2 exh flange-downpipe bolts - both assuredly just as rust-welded as the first - be careful, use lots of Liquid Wrench or equivalent.

And then remove the bolts/studs holding the entire exhaust manifold to the head. Again, lotsa Liquid Wrench.

Take the manifold to a competent garage and have them remove/install fresh studs in the "downpipe flange" of the exh manifold. And get matching nuts while you are at it.

Not a difficult job, just very time-consuming as you wait on the Liquid Wrench to do it's job. Take your time as you don't want to risk breaking a manifold stud in the cylinder head itself.

You will likely find that the nuts are rustwelded to these manifold studs too, so you may as well refresh these with new.

IMHO, it is false economy to re-use old bolts that are subjected to such an extreme environment as the ex manifold area.

Unless you also really want to remove the intake manifolds above the exh manifold, then I would not replace the entire intake/exh manifold gagsket.

I would just wipe off the exposed exh manifold area of the gasket surface with some turpentine on a lint-free rag, and slather it with a film of antiseize paste. Although some may suggest a thin film of hi-temp silicon paste. Ask the exhaust guy at the garage that is fixing your flange studs, for a suggestion.

You ABSOLUTELY want to use a new exh flange-downpipe gasket, again slathered in antiseize. Don't take a chance here.

Good luck.