Starting HG job reassembly. I'm following Atlantic British's directions in combo w/RAVE. Doug says to replace the 3 studs to the catalytic converter so I bought 3 studs. I have two issues...

1) I can't get the bloody stud to budge out of the exhaust manifold. Doug says to twist with a needle-nose plier. That is definitely not going to work. Should I drill it out?

2) I didn't buy studs for the passenger side manifold. Should I replace the studs on the passenger side too? Doug doesn't mention this in the video.



Passenger's side

Driver's side

 

Probably going to have to use some heat, use a quality vise-grip or double nut stud, heat manifold around stud and remove. Extinct Motorsports Engineering has a better option for studs and nuts, he's listed above in sticky.

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Just because Doug recommends replacing the studs doesn't mean it's required. Sometimes "If it ain't broke[n] don't fix" applies. This may be one of those times.

 

I use a stud removal socket like below, never had problems.

 

Your timing is perfect! We just launched stainless replacements. BTW, soak your existing ones in aerokroil for three days straight and they should come out with a little back and forth work. You can jam two nuts together on the stud to get a grip on it. Sometimes you have to weld a nut on the end to get them out.

Here are the stainless replacements: https://extinctmotorsports.com/exhaust-studs

 

Recent head gasket job.

Had to replace 1.

Heat, penetrating oil and vice grips.

 

I only replaced what broke on the way off. I can't remember if I had to mill one or two that broke in the manifold, but it was at least one. Two others were broken but with enough stud still showing to get locking pliers on. Kroil, heat, clamp pliers and jiggle back and forth, repeat. Took about an hour, but I did get those two out. Take your time and go slow if you are going to remove them. Get them good-n-hot.

 

Yours look in pretty good shape so not sure I would be too concerned with replacing them. I got mine out with a torch and needle nose vice grips. If one breaks off don't screw around with an extractor, just drill it out and Heli coil it. If you break an extractor off in it then you are in big trouble.

 

You can get a die to clean up the threads, as well.

 

And whatever you do make sure you use anti seize compound on the threads when you reinstall.