Saab 9000 exhaust manifold gasket

[ms08]

I need to replace this but from experience suspect will have issues with broken/rusty manifold studs which may need drilling out in situ.
Any suggestions please as to best way to do this and best drills/stud extractors to use/left handed drills etc?
I have a battery drill with right angled head to get in there but do i also need to use/make a guide for the drill, centre punch them, soak in preferred release solution first?
Any tips appreciated.....

 

[Mark 5]

I need to replace this but from experience suspect will have issues with broken/rusty manifold studs which may need drilling out in situ.
Any suggestions please as to best way to do this and best drills/stud extractors to use/left handed drills etc?
I have a battery drill with right angled head to get in there but do i also need to use/make a guide for the drill, centre punch them, soak in preferred release solution first?
Any tips appreciated.....

IMO, remove the manifold altogether, soak studs in a releasing agent, repeat, heat the area around stud, ( not the stud ), use your extractor.

Point being easier to do stud work on a manifold, off the car where possible.

 

[Kram]

Preferably drive it a bit and run the engine up to temp. They will be much easier to remove with a bit of thermal expansion.

 

[steveo3002]

any access for splitting the nuts with a good chisel ? leaves the whole stud to deal with later?

 

[Smallfry]

Do you mean manifold to head, or turbo to manifold ? Never worked on a SAAB but normally stainless studs and nuts are used for the turbo, but they tend to disintegrate.
Plus gas is your friend, and as said, I would try loosening it with engine hot, and possibly even running if they are that bad. Will need to wear gauntlets and protect arms too. Patience is they key, not that I have any !

 

[ms08]

Hi
Manifold to head. I will get a couple of pictures done and post up. I am inclined to to this cool rather than hot as it gets sh** hot with the turbo attached.
The studs normally shear at the point they go into the head.

 

[jenki]

Had this on a 99 Turbo in the 80's I had a guide turned up and used a hand drill to drill out the remnants the stud had broken about 4mm below the head face. I think in your situation I would soak the studs/nuts in Plusgas whilst the engine is warm a few times.
Are you able to get one of these onto the nuts?

Hilka Pro-Craft Nut Splitter Set 2 Pieces - Screwfix

Order online at Screwfix.com. Sturdy forged high carbon steel body with chrome vanadium blades. Hardened and tempered for durability with satin finish for rust resistance. Cuts off rusted, cross-threaded or rounded-off nuts without damaging bolt thread. FREE next day delivery available, free...

www.screwfix.com

Good luck.

 

[ms08]

I am thinking along those lines of making a jig if all else fails but also watching the other thread on here removing a broken stud....

https://www.mig-welding.co.uk/forum/threads/welding-a-nut-on-to-cylinder-head-bolts.138638/