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[omegod]

Well I seem to have made a schoolboy error when fitting a new gasket to the drivers side downpipe to manifold joint, due to the nightmare access( 3 extensions!) I seem to have misthreaded one of the 15 mm nuts and the thread seems mangled, resulting in it not sealing and blowing, it needs to be a fair bit further down the thread than it is

I guess the only option is to replace the exhaust manifold, OH F******CK but I am happy to try ANY bodge that may work and get a seal on this joint so spanner wielders of OOF give me your best suggestions!

[Elite Pete]

Manifold off i'm affraid Jon

[mantahatch]

Is it worth trying a die of the correct size and trying to recut/clean up the thread ?

[omegod]

There is bugger all access, just about get a socket up there

[mantahatch]

There is bugger all access, just about get a socket up there

Remove downpipe/cat first and you should have reasonable access. 

[amba]

Possible solution would be to get a stud removing socket such as an Irwin on a couple of long extensions.

You will need to remove the cat to give yourself a bit more room to work,but you may then be able to free the exhaust stud from the manifold.That way you then can replace the entire stud and fit a new copper nut and seal up as new.

Sounds possible as you have little to loose,and will save removing the entire manifold.

Best of luck with it.

[Martin_1962]

Copper nuts are used - is the stud thread OK?

[omegod]

Copper nuts are used - is the stud thread OK?

I think it is the stud thread that is mashed sadly! any type of nut available that will grip/cut it's way up? sounds daft but if the threads buggered it's a new manifold anyway so anythings worth a try just to rather seal it,believe me, I won't be going there again'!!!!!! one of the two nuts  is done up nice and tight but obviously needs to be well tight to seal.

[amba]

If you still have abit of thread on the start of the stud,would it not be possible to shim off the face of the exhaust flange with a few washers or an oversized nut and then get the copper nut to tightened up against them .?

[Cliffo B]

how about this?could be worth a try.go to your nearest engineering tool supplier and get die nut thread cutter then lock this in a socket and re cut the thread with a gentle twist untwist and plenty of oil,all depends if theres enough space to take the socket surounding the stud,hope this helps,best of luck

[omegod]

how about this?could be worth a try.go to your nearest engineering tool supplier and get die nut thread cutter then lock this in a socket and re cut the thread with a gentle twist untwist and plenty of oil,all depends if theres enough space to take the socket surounding the stud,hope this helps,best of luck

Sounds like a plan..Does anyone know what size thread the stud  is please? 

[JamesV6CDX]

As a short term bodge, if you have at least a nut's worth of thread on the end of the stud, just use some form of spacer(s) on the damaged thread, and tighten against the good thread.

Longer term -

Cat off --

Good soaking in plusgas

Attempt to extract entire stud.

If this fails, it's manifold off....

[alank46]

As a short term bodge, if you have at least a nut's worth of thread on the end of the stud, just use some form of spacer(s) on the damaged thread, and tighten against the good thread.

That is what I would do.  As a spacer use the next size up nut, or the correct size nut with the threads drilled out.
Alan

[ffcgary1]

If you go to your local Machine Mart you can buy some stud extractors that fit your extenstions, remove the stud and replace one or better still both studs and nuts with new. I have them and they are fantastic.

[Bent valve]

The thread size is M10 X 1.5.
Get a die nut this size thread it onto the stud and tighten it up hard. Then get an M10 Binx nut, which is basicaly an aircraft grade locking nut and tighten this up as hard as you dare against the die nut.
Both these nuts are readily available from your local engineers merchants
EDIT, I have just had a look at a spare manifold in the garage and there isnt enough space between the stud and the downpipe to allow a die nut and socket to clear, as they are considerably larger than a standard M10 nut.
 Instead you could try cutting through one side of a standard nut, fitting it into a socket and threading that on to the stud to try and clean up the thread.