Exhaust studs snapping :(


Scottek

Scottek

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Joined
Sep 28, 2010
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The studs that hold the manifold all sheared off not long after I had my turbo setup done.

I got them drilled out and then replaced them with high tensile bolts and they have gone and sheared off at the head again. Only the two outer studs (original ones) didn't shear off so are still there, and they are all that is holding the manifold down.

Anyone had this problem and have a solution? Possibly a support bracket as clearly the studs can't take the weight of the mani and turbo.

As standard, are they all studs with nuts on? Or are they just 2 studs and then the rest bolts?

Cheers
 
Everything must be moving to much under acceleration. I would try and add extra support somewhere if possible. The extreme heat won't be helping but there's not a lot you can do about that. Post some pictures of your engine bay up so we can have a look
 
oem its just the two outer bolts and the rest are studs. As said it looks to be a combination of the increased heat and load on the bolts that are causing them to shear off. A support bracket on the downpipe could help take the weight off the studs.
 
Cheers, yeh I thought a bracket would help, just not sure where to fix it? I can make it in work easily enough.

Ill get a pic of my bay later.
 
My car has been turboed since 2007/2008 and all the exhaust studs are still the original? Mine isnt supported either.
Stupid question but are you copper greasing the studs when you put them in? Also what studs are you replacing yours with? The weight of the turbo plus manifold alone wont be able to shear 9x8mm studs?

Murray
 
Can't answer those as I never did it myself, It happened just before I went on holiday and tdi north sorted it for when I got home.

All they said was the were high tensile bolts, and they seemed to be made from SS.
 
They should be mild steel studs/bolts not stainless!!!!

If TDI North fitted them and charged for them I'd be fuming! Surely a company with their experience realise that putting the weight of a turbo manifold/turbo/downpipe onto stainless steel bolts will result in shearing? Stainless is not as tensile as mild steel, hence why they don't use them in suspension components etc where the bolt/stud is under load/stress!
 
Just looked in my bay and its only the bottom ones that have sheared. They have discoloured a fair bit and the bolts are discoloured a fair bit, no rust, but are not shiny.. I thought mild steel would of atleast had some surface rust on them?
 
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Here's some pics, hard to see but what do you reckon they are made from?

CDEC6617-7A70-42F7-BC15-7247EF43EF2F-7184-000005ABB792651A_zps961a3061.jpg


F7FF4BA1-3D6A-4EDD-8507-99397CC896E9-6644-000004FD52DDFF46_zpsf1ccd680.jpg


I can get some better pics later as I've got my bumper off now.
 
If its just the bottom ones that have sheared then in definetly aint the weight of the turbo etc.
IMO they should be studs instead of bolts aswell, and not stainless as said above.
Looking at the pics, the bolts are not stainless anyway, if they were they would be discoloured differently. They just look like cheap shite.
 
I think a mixture of cheap monkey metal bolts and possibly a warped manifold flange if snapping bottom bolts. Best way to check is to place flange on a flat glass table and check for warpage. Like murray said they should be studs as well to take the torque load away from the head.
 
Alright cool thanks guys. Ill check to see if its warped. Is it possible to get a set of oem studs?
 
Probably due to cheap **** bolts and maybe warpage in the manifold.
Use studs. And never have a problem.
 
I've had one snap on my turbo setup . I'll replace it with another one and if it happens again I could always get upgraded ones
 
I had this happen a few times. Usually after a flat out run. Full boost full speed for a few minutes. The fabricator I know cut slots in the manifold flange and it's been fine ever since
 
Make sure the manifold face is flat and not warped. Or else you will be trying to pull that flat. Giving the studs a harder time.
 
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