Is there a technique that delivers a good success rate for removing the studs from the manifold face? I would like to have the manifold face lightly milled, during the head rebuild process, just to true it up for best sealing, but if I am likely to bust the studs during removal, I may re-think that. I have been dripping rust buster at the base of the studs for a week.

I've always been able to get the studs out when rebuilding an engine, and the only breakage I've encountered has been while the car was in service. Your experience may vary. Since you're taking the block to a machine shop, the easy way is to have them removed where they have the equipment to do it right.

FWIW, If it was mine, I wouldn't worry about surfacing the head. The manifolds are usually so warped that they are in far worse shape than the head.

The last one I did was so warped that I had to loosely assemble the manifolds to the head to align the bolts, then tighten the manifolds together and take the assembled manifolds to the machine shop to have them trued. Even after every manipulation I tried, it was still twisted about 1/8", but now they seal just fine.

A cam type stud removal tool is the tool you need.
KD Tool #1708 is the one I have and it works well.
$28.00 from this on-line store
My local discount auto parts store also carries it on the shelf.
DD

Don't worry about breaking off the studs now, worry about breaking them off when the engine's installed and in service! If any of them breaks off now, it would've broken off on manifold installation (or soon thereafter) leaving you with a much bigger damnuisance to deal with. Replace all the studs with new while the head's out.

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一期一会
Too many people who were born on third base actually believe they've hit a triple.

I've been very successful in removing studs by using two nuts on a stud with the nuts tightened against each other and unscrewing the stud. A pair of 1/2" wrenches, two nuts and some effort is all it takes.

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Joshua

thanks, all great ideas, I now have something to work with.

When you reinstall the studs use loctite so water won't leak and ruin your nice gaskets and use brass nuts on them so you won't snap any off during assembly. I bought a little longer studs so assembly is much easier and few extra brass nuts! Don't forget to pick up two new castle nuts for the ends.

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Aggressive Ted

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