Bongo Fury

Having read all the problems associated with sheared no. 1 stud my problem is no 8 stud. The slight whine on start up and moving off doesnt bother me much but I am more concerned about possible damage in the future ! Should I be ?

the thing is the longer its left the more the thing will warp out of true

put your location in your profile and peeps local to you might be able to help you

Hmm, Plenty assume that the stud goes, then the manifold warps... When in fact, the manifold warps, which makes the stud break, then another, then another...

Right. Seems like the job needs to be done. I know there is plenty of help and advice available on the site but to anyone who has done it what chance the other 7 studs coming off without any shearing and any other associated problems ?

i did ours a while back,no 1 stud sheared off, soak everything first overnight. remove the 22mm pipe to the egr that exits the manifold on the right hand side first,as its bloody tight, it may need some heat to release it.
remove exhaust and drop away. remove rear half of turbo by splitting at the band around the centre,watch the little locating peg that lines up the 2 halves. by removing just the rear half you dont need to break into the coolant system.
watch the 2 oil pipes.
remove the manifold studs and manifold and gasket.
check the manifold for being flat, mine was miles out and needed machining.
drill out broken stud,or remove if you can, replace all manifold studs as 2 others of mine were about to break.
use hot side(heat treated studs) not inlet (cold side studs) to replace them. land rover studs are the same as a bongo,and are a lot cheaper.
new tin gasket,refit, jobdone.
i reused the gaskets between the manifold and the turbo,and turbo to exhaust as they cleaned up well,get half a dozen spare nuts(heat treated) for the rebuild as several of mine were damaged when removing the turbo/manifold/exhaust.

good luck.

Right, thanks for that help. Getting started on the job next week.