Bongo Fury

See other techie post headed Turbo Problems?

So my garage has finally admitted that the 'lawnmower' noise could be attibuted to the fact that number 1 manifold stud has sheared....not the turbo packing up....aso I've got a manifold gasket from AVA and my garage is going to do the job next week.

Now they are good mechanics but always welcome a bit of guidance...also saves my labour bill (they used the notes re cam belt and did the task in under an hour having previously estimated it as a two to three hour job without the notes).

PLEASE...has anyone got any notes/experience that they can pass on so my garage isn't faffing around.

cheers

H

Hello...is anybody there???

Surely someone has some helpful hints?

H

Have you done a search on the subject?

Yes...I've searched but not really come up with any cohesive information.
Still hoping that some kind member will help with my labour costs...maybe just a sequance of jobs?

H

I removed the heat shield from the manifold and took off the alternator (disconnect battery first!). I'm not sure what else I took off but it only took a few minutes to get to the busted stud!
I tried drilling the stud out but it just wrecked my drill bits! I even tried sharpening a masonary bit but that didn't want to play either.
The best way to do it, which was how I should have done it in the first place but couldn't be bothered to drag the welder out, is to build up whats left of the stud with the welder. I used a TIG set but have used gas, MMA and MIG in the past.
Once you have built up a bobble, either grip it with the Mole grips or weld a nut onto it. The heat from welding loosens the stud and it will happily come out.
I fitted a new stud with anti-sieze compound and nipped up the manifold and I've had no bother since.
HTH

There has been a lot written on this. I took my manifold off and bought a new set of roller stud extractors to grip the remaing stub of the stud. It then snapped flush with the head. I took several hours and drills to extract the stud before i could tap a new thread. There is water cooling to the turbo so be prepared to block pipes if you remove other wise you will loose coolant. The studs are a common size.