Titanium Grey S4 Avant

[diesel des]

At times like this I have had a local machine shop machine me a stud with say m10 at one end and m8 the other assuming an original m8. Then drill and tap the original hole to m10 and put that side of the stud in. I have more luck with this repair than thread inserts.

[andy10v]

This is s job for Mr Dremel

[newsh]

This is s job for Mr Dremel

Dude, I wasn't going to go there.. Where's Madwolf when you need him??

[Error404]

This is s job for Mr Dremel

[hunker7]

That's the best shot, but tried it yesterday without any luck. Maybe will try some bolt extractors.

[newsh]

Ok, maybe you can get a pick in there and hook the thread out, then drill and tap and fit a Timsert.

[hunker7]

That's the one. I can't screw it back on because thread is non existent. I literally pulled the broken half out with the stud, which makes me think the thread has been badly done when fixing it.

It came off as I wanted to change manifold, gasket seemed to be blowing slightly and it gave me a better access to get it all cleaned up.

[newsh]

Oh, it's one of the exhaust manifold studs in the head? Can you not just screw the thing back in with the helicoil on it? Why did you take the exhaust mani off?

[newsh]

Is it one of the downpipe studs on the outlet of the exhaust manifold?

Show us a pic of the bit that came out and the location of the stud that you mean.

[hunker7]

Not really. Judging by the piece that came out there is about a half left in there.

[andy10v]

Can you get a picture of what is left?

[hunker7]

Should mention it's at the very end where downpipe is.

[hunker7]

As usual something HAS to go wrong.

Basically one of the exhaust stud holes have had a thread repair in the past, and what happened when I was removing it broke the thread insert in half, so now I can't drill it out. Any suggestions that doesn't involve removing head?

[andy10v]

Looking very clean.

[UrS4boy]

...P.S. Yes, I know I have the cover on and it will shorten the life of coils

YUP. It will. Guaranteed.