Madwhip Member 73 Member For: 16y 1m 7d Posted 27/05/11 02:39 AM Share Posted 27/05/11 02:39 AM Does anyone out there make a replacement manifold that retains the factory dump pipe? I just snapped a stud in my manifold and I'm sick of m having an exhaust leek every other month. I want to fix this one last time. I have found Nord locks stopped the nuts working loose now the hole stud just drops out. Just to be clear I'm talking about the 4 studs that hold the turbo to the manifold. I spoke with Ford and they said they just fit what ever is lying around . I think that's how they designed the manifold. Oh look here is a NA manifold fit a flange on it and she will be sweet damn ford and there short cuts. Link to comment Share on other sites More sharing options...
Ralph Wiggum Moar Powar Babeh Lifetime Members 19,323 Member For: 19y 2m 1d Gender: Male Location: Perth Posted 27/05/11 04:10 AM Share Posted 27/05/11 04:10 AM Remove manifold, take to competant machine shop, remove broken stud,refit new studs refit manifold/turbo etc.There are also plenty of mobile guys who specialise in removin broken bolts/studs, remove the turbo and get one such guy out to do it Link to comment Share on other sites More sharing options...
bjc Donating Members 2,823 Member For: 21y 2m 21d Gender: Male Location: Townsville Posted 27/05/11 06:16 AM Share Posted 27/05/11 06:16 AM How tight do you screw the stud in first as that may be the problem? Did you use two nuts nipped up together on the stud to get the stud screwed in and biting tight firstly before adding the nord nut and washer? Link to comment Share on other sites More sharing options...
Madwhip Member 73 Member For: 16y 1m 7d Posted 27/05/11 06:27 AM Author Share Posted 27/05/11 06:27 AM I can remove the broken stud that's not my issue. I just want a setup that I don't need to keep working on. I have never had this issue with any other car. I was thinking of adding a spot of weld next time but this is only as I'm at wits end with it. I only get about 2500ks before I have to replace or re-tighten the studs. I could cut the flange off the manifold mount it with a v-clamp but that is a pain in the butt. I have owned the car 2 years or so and gone through 6 studs from them dropping out. It takes the pleasure out of owning a nice car when it needs constant work like this or I turn the stereo up so I can't hear it but the power loss is not fun. And car guys can hear the leak and look at you funny Link to comment Share on other sites More sharing options...
Madwhip Member 73 Member For: 16y 1m 7d Posted 27/05/11 06:30 AM Author Share Posted 27/05/11 06:30 AM How tight do you screw the stud in first as that may be the problem? Did you use two nuts nipped up together on the stud to get the stud screwed in and biting tight firstly before adding the nord nut and washer?yes I used two nuts. I'm wondering if the one that keeps dropping out has a crack running from the edge of the manifold to the screw hole it's the bottom rear. Link to comment Share on other sites More sharing options...
Ralph Wiggum Moar Powar Babeh Lifetime Members 19,323 Member For: 19y 2m 1d Gender: Male Location: Perth Posted 27/05/11 06:38 AM Share Posted 27/05/11 06:38 AM (edited) How tight do you screw the stud in first as that may be the problem? Did you use two nuts nipped up together on the stud to get the stud screwed in and biting tight firstly before adding the nord nut and washer?Tha is my "normal" stud install method but its caused me nothing but problems on these cars (ie studs that siezed and snap when removed.)I now put the stud in finger tight, torque the nut to spec and use a mechanical locking system IE Nord Lock (very very good!) or Posi Locks (excellent but firkin Exxy!)ive not had any broken stud or loose studs since doing install with this method@ the OPDude you must have another issue. Do you run a gasket between the turbo and the manifold? Are the manifold and turbine housing faces flat? Are you using quality studs/nuts when you install?Oh I more thing Always install them, run the car up, let It cool completely before retorquing Edited 27/05/11 06:42 AM by hiddeous Iphone spelling fails! Link to comment Share on other sites More sharing options...
bjc Donating Members 2,823 Member For: 21y 2m 21d Gender: Male Location: Townsville Posted 27/05/11 06:41 AM Share Posted 27/05/11 06:41 AM (edited) possibly a crack with the one that just drops out easily but the others are coming loose to quick I'd think.Have you tried contacting maybe ETM or 6boost as I know someone makes another style of lock nut and stud kit but its not cheap like $130 or something. I tried to find ETM's webiste but fck knows where it is! Just read it above from hiddeous, the Posi Lock may be it but I cant remember who makes or sells them? Edited 27/05/11 06:51 AM by bjc Link to comment Share on other sites More sharing options...
Madwhip Member 73 Member For: 16y 1m 7d Posted 27/05/11 07:06 AM Author Share Posted 27/05/11 07:06 AM Thanks for the suggestions guys.I have found the nord locks perfect for two of the studs no problem with them but the other two come loose often and one of them the rear bottom is just a joke every time I check it it's either gone or loose. I sent a message to (Leigh)mr etm to see what he can offer. His web site was not working. When I had the turbo off to do the waist gate mod I checked the faces and they were sweet.Butt this was over a year ago and 3-4 studs since then I have not had the turbo right out. When I put the turbo back I used a quality gasket and studs it was fine for about 1000-2000kms but then loosened up blew the gasket so I never used a gasket again. I have never had a turbo car that did not have a gasket there but checked with Ford(LOL). I might give it one more go. Take the manifold and turbo out and mount them on the bench. I'll just not use the support bracket when I put it back together. What a pain in the butt job for a problem that should not exist. Link to comment Share on other sites More sharing options...
bjc Donating Members 2,823 Member For: 21y 2m 21d Gender: Male Location: Townsville Posted 27/05/11 07:11 AM Share Posted 27/05/11 07:11 AM Yeh everyone says to leave that fcker off as it does nothing! Link to comment Share on other sites More sharing options...
Madwhip Member 73 Member For: 16y 1m 7d Posted 27/05/11 07:16 AM Author Share Posted 27/05/11 07:16 AM Yeh everyone says to leave that fcker off as it does nothing!I was going to leave it off but it just looked so hefty that I figured it was needed. As I'm sure Ford added as little as possible when they built the first of the turbos Link to comment Share on other sites More sharing options...
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