Broke an exhaust manifold stud on the collector end...

This is on my 300 SRT8 with catalytic converter problems...

Grind flat and drill out, or are there other tricks?

Looks like it's pressed in. I suppose I could heat it up and beat on it?

Thanks for any suggestions.

"Grind flat and drill out, or are there other tricks?"

that...if you beat on it you might bend the flange.

Can you feel if there are threads on the top side of the stud?

If there are no threads, then grind it flat, drill it out and tap it to thread it.
That or drill it out and use a bolt and nut (which is what most cast iron manifolds use).

The stud may have been welded in place on the factory headers like that.

Edit:
After doing an online google search of pictures of factory SRT headers I see some with no studs in the collector end making me thing that they are removable, as in threaded in.

Grind, drill, tap is your best option.

Looks a 'yota stud that uses a torx socket. I agree with grind, drill, and tap.


Tim

Weld a nut to it. It'll come right out.
Doug

I have never heard of an exhaust stud being pressed or welded in. It looks per picture there is not enough of the stud to get a vise grip on to it so as stated above weld a nut on it, then heat the flange and turn it out. Might as well remove the other one also, heat the flange first, grip it with some good vise grips, pipe wrench or a stud removal tool. Replace with proper studs and brass nuts.

Turns out it was threaded into the flange. I welded a nut to the remnant of the stud (full fusion too) but it just broke off when I tried to back it out. Ultimately had to drill it out. That sucked, but it's done...

Thanks guys

An experienced exhaust man would blow that out with a torch and never touch the threads in the manifold. Takes about a minute including lighting the torch.

next time weld a flat washer to the stud, then weld nut to washer. when cooling saturate with penetrating oil, let cool and remove

Very true, done a ton of them. But that's not for a beginner.
Doug

Last one I was working on I ground it flat, cut the head off a bolt and welded the stud to the flange. Tried drilling it out but it was in an awkward spot to get a drill.