So when cleaning my EGR this weekend I have stupidly over tightened the nut and thread on the exhaust manifold that the EGR flexi pipe attaches too and snapped the whole stud off......

 

Just called TPS for price on Exhaust Manifold...Turns out it comes with a turbo attached? Is this correct? can I get just get a manifold? 

 

My ass is clenching as we speak lol

 

LeezoG

It doesn't sound like a critical fix, can you secure the flexi another way or use the car without securing it at all?

Its secured on with the other bolt with new gasket, I been driving around for a day or so with it like it and it is blowing a little. Im just worried it will cause some issues in the long run. I was planning on a EGR delete but now cant even blank it off properly. 

 

Litrally sat here kicking my own arse for snapping it. Think its gonna be a drill it out jobby and replace the stud.

 

Car seems to run ok. other than it blowing a bit. And no lights on the dash ect so cant be that bad?

Looks that way. Here's a googled image of the turbo part number 038253010T which I believe is what your car has.  Exhaust manifold integrated with turbo housing.

 

 

Which stud has bust, the left one in the above pic or the right one? If, by a miracle, it's the right one, you could just clearance drill it out, and nut-and-bolt it, if drilling and re-tapping doesn't go well.

 

Edit: Even if it's the other one, looks like there's plenty of metal to go into, and it should be about as hard as the stud, so shouldn't be too difficult to drill and re-tap. Not like a steel stud snapped in aluminium alloy, where the drill wants to go anywhere but down the stud.

Looks that way. Here's a googled image of the turbo part number 038253010T which I believe is what your car has.  Exhaust manifold integrated with turbo housing.

 

 

Which stud has bust, the left one in the above pic or the right one? If, by a miracle, it's the right one, you could just clearance drill it out, and nut-and-bolt it.

 

Edit: Even if it's the other one, looks like there's plenty of metal to go into, and it should be about as hard as the stud, so shouldn't be too difficult to drill and re-tap. Not like a steel stud snapped in aluminium alloy, where the drill wants to go anywhere but down the stud.

Yes bud its the two studs on the right of the pic pointing upwards. the right hand one of the two Praise the lord its a miracle??? :P......So hopefully get it drilled out and use a bolt and nut or whatever. Just got quoted my TPS £860inc vat. Seen a second hand jobby on ebay for £299. Worst case second hand one. But think ill be getting it drilled out.

Edited 9 December, 201411 yr by LeezoG

I made an edit to my post above, but after you've quoted it. You may as well try to drill the stud out and re-tap for a replacement stud, rather than drilling it oversize straight away. If your re-tapping doesn't go well, you have the fall-back option of drilling oversize for nut and bolt. :sun:

I made an edit to my post above, but after you've quoted it. You may as well try to drill the stud out and re-tap for a replacement stud, rather than drilling it oversize straight away. If your re-tapping doesn't go well, you have the fall-back option of drilling oversize for nut and bolt. :sun:

Yeas mate I jumped the Gun, Think drilling and retap is gonna be up 1st i really cant afford to be forking out this time of year and got a little boy due in march this is supposed to me my family car.....Much to the Missus' Disapproval. All these lil things aint doing very well at fighting my corner lol.

want an easy fix

 

remove the EGR completely, make sure you clean up the manifold area so it clean metal around the snapped stud

 

fit your blanking plate and then lightly tighten up one side then get a pair of grips and clamps the other side (don't cover the bolt hole though

 

then get a mig welder (remove battery + terminal)  and weld up the hole where the snapped stud is, if done correctly it will fuse with the snapped stud metal and create a puddle in the egr blanking hole and this will hold the plate in nice and tight, let it all cool down and then tighten up the other side start engine and see if it leaks

Even easier, MIG weld a nut to the broken stud and undo and remove it.

 

Gives you options.

want an easy fix

 

remove the EGR completely, make sure you clean up the manifold area so it clean metal around the snapped stud

 

fit your blanking plate and then lightly tighten up one side then get a pair of grips and clamps the other side (don't cover the bolt hole though

 

then get a mig welder (remove battery + terminal)  and weld up the hole where the snapped stud is, if done correctly it will fuse with the snapped stud metal and create a puddle in the egr blanking hole and this will hold the plate in nice and tight, let it all cool down and then tighten up the other side start engine and see if it leaks

Yea was planning on deleting EGR anyways, So that is an option. But I cant even tighten up a nut without snapping threads.....MIG welding possibly not such a good idea to DIY   Plus Id like the option of being able to put EGR back on If i so desire, But thanks for the Input.

Even easier, MIG weld a nut to the broken stud and undo and remove it.

 

Gives you options.

LOL there is no stud to get hold of mate. Its sheered off nice and elvel just to make things  a lil more difficult

LOL there is no stud to get hold of mate. Its sheered off nice and elvel just to make things  a lil more difficult

 

You can still puddle weld it, trust me.

You can still puddle weld it, trust me.

I couldn't even tell you what a puddle weld is buddy....I trust you......I dont trust myself lol

I couldn't even tell you what a puddle weld is buddy....I trust you......I dont trust myself lol

 

Get someone with a MIG to do it for you.

Get someone with a MIG to do it for you.

Is that easier than drilling it out? 

Is that easier than drilling it out? 

 

Much, and quicker too.

Much, and quicker too.

In that case I shall take it off the weekend and take it to someone to do that. Cheers Bud.

Thanks for everyone's advice. Your all stars! Ill keep ya posted. 

Edited

I miss read weldinf a nut to the stood sounds good too me aswell

Edited 9 December, 201411 yr by fletch101

Yea well Iv just spoke to a mechanic in work and mentioned removing the exh manifold...I got all sorts of expressions from his face lol. He said its gonna be a utter ballache to remove it. Anyone had any experience with this? Thinking/Hoping there is enough thread to get a nut onto. Will make my life so much easier and cheaper!