I had a slight leak at the junction of manifold to pipe gasket, which I finally decided to fix it but run into problems. I took 2 bolts off and the third one came out with the stud. I put the 2 bolts back on, which was not difficult and went to get new studs and bolts. The 2 remaining studs were not coming off easy, they were turning with a lot of resistence, so I decided to leave them in place and put one new stud and while puting the bolts back on, one of the studs broke. Not from over tightening but I might have put the wrong/stripped bolt on. the stud that broke was not frozen in place, since i was able to turn it before it broke.
I took the car to a local shop, which is also suppose to be an exhaust shop. they said they will charge me 40 dollers to remove the stud, which was actually sticking out at least a third of an inch. This sounded reasonable and I said OK. An hour later the guy came out and said they did every thing and even welded a bolt to the stud and they couldn't get it out and that they can no longer due it for 40$ since the stud is completely frozen and they might not even be able to have it done today and for 120 I could pick up the car tomorrow. I did not see anybody welding anything and told him no, I want to take the car back home. he said he even dropped the exhaust to take it off.
When I left his shop, ultragauge warned me of pending codes and they were P0134 and P0135, which are related to O2 sensors. I called the guy back and told him if they disconnected the O2 sensors, they said no. I cleared the codes and they came straight back and the car stays in open loop. After the car cooled down, I crawled under it and noted that they broke 2 other studs on the oposit side, which I didn't even touch previously but did inspect it and every thing was in place. Now one stud is broken almost flashed with the manifold and the other one is broken off and they were able to get a bolt barly on to keep the pipe connected.
They did not tell me anything about what they broke and just gave me the car. Obviously the shop was closed by the time I discovered all of this. I will visit them tomorrow again, but what options do I have in situation like this if they are not willing to correct, what they broke.
for me the 2 bolts came off easy, I guess because I soaked them in penetrating spray and waited for quite some time.

 

Don't worry about the O2 sensor codes.
Those are coming in because you are getting AIR into the exhaust
via the broken studs and the leak after the manifold.
Once you get all that back together properly, you'll not have O2 codes.

You can get studs from
rimmerbros.co.uk

There is a little socket tool that will pull out studs.
But, yours is really in there.

I would get a whole new manifold from eBay and get new studs and do it that way.

Or, else

You need to pull the manifold.
Drill out the stud if possible.
Get a tap and tap in the original thread if possible.
Or, if not, put in an oversize thread and stud.
But, that will mess up the fitting of the collar from the Y pipe.

I would get a new manifold from eBay and call it a day.

discovery manifold | eBay

If I did get a new manifold from eBay I would try to put new studs into it.
Don't buy an eBay manifold without studs.
Threads can be stripped in the manifold.

Actually, drilling out your stud is sounding better and better.
My studs were so bad.
I was able to get them OUT with a stud Snapon Stud removal socket.

I than used a tap to retap the threads.
Put in new studs from Rimmerbros which I ordered.

I just did the heads on my Discovery II.
And, thankfully DID NOT have to mess with the Y pipe and studs.
Left the manifolds BOLTED to the Y pipe and just pulled off the heads.

 

Thank you for the advise, I had to take the manifold on my old D1 for the same reason and stripped a couple of the manifold bolts. I must say that that car was very rusty (1997).
I was upset about the shop not telling me that, they broke 2 studs, I went there today and confronted the guy. I told him that he didn't have the decency to tell me what happened, if I knew what happened we could have worked it out. He didn't deny or admit anything, but said bring it back and he will fix it for $80. I will drop it off monday. I don't want to break or strips more bolts.
I am really having bad luck with mechaniks (actually shop owners including big dealerships) not being honest.

 

Sorry to hear that.
If they are not up front - they may be short cutting on other items too.
I would do it yourself - or find another shop.
The rover I bought had some bolts out here and there from the
SAI. But, that was about it.
I can't call them on that. As it was not may truck yet.
And, those bolts are painful. Ha, I skipped them too!

 

Always pay with credit card so you can dispute poor work

 

Thats a good idea, I disputed a charge once, and it was a long process.