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Engine, Exhaust, Transmission Discuss the FR-S | 86 | BRZ engine, exhaust and drivetrain.


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Old 05-03-2020, 12:24 AM   #1
toughguy39
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Header and Overpipe stripped bolt

So I bought UEL headers and was planning on getting them installed today when the worst thing happened... one of the bolts from the headers to the overpipe stripped even after using PB blaster. So I bought an overpipe after doing some research and plan to install that along with the headers. Just wanted to make sure but will there be enough room with both shields off to pull the overpipe along with the headers out? If not what would be the best option to get this bolt out? Thanks in advance.
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Old 05-03-2020, 12:28 AM   #2
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I don't think you can get the over pipe out without rotating it like 90 degrees.

So you are going to either have to beat a smaller socket onto that nut and then rip it off with an impact gun (this requires that the socket be sacrificed), Or get in there with a grinder and cut that bad boy off of there.
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Old 05-03-2020, 12:32 AM   #3
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Yep, there's nothing to except the threads that are stuck haha, soooo yeah, I don't have a grinder, might need to get one for this.
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Old 05-03-2020, 12:46 AM   #4
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Originally Posted by toughguy39 View Post
So I bought UEL headers and was planning on getting them installed today when the worst thing happened... one of the bolts from the headers to the overpipe stripped even after using PB blaster. So I bought an overpipe after doing some research and plan to install that along with the headers. Just wanted to make sure but will there be enough room with both shields off to pull the overpipe along with the headers out? If not what would be the best option to get this bolt out? Thanks in advance.
Just unbolt your motor mounts and jack it up. Then you should be able to slip it out.
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Old 05-03-2020, 02:53 AM   #5
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Vice grip pliers.
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Old 05-03-2020, 09:04 AM   #6
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Originally Posted by weederr33 View Post
Just unbolt your motor mounts and jack it up. Then you should be able to slip it out.
This guy has the easiest solution. Had not though of that, you can easily get 2 inches of clearance or better and everything should aide out whole.
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Old 05-03-2020, 09:45 AM   #7
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Is the nut turning and not coming off? You can use a nut cracker to split the nut off or very carful use of a grinder. Then remove the pipe and then blast the stud, and remove with stud remover or perhaps Vice grips.
Do you mean that the nut sheered off the stud? Remove the pipe.
Then PB blast the stud that is exposed and then stud remover or try a vice grip. If it breaks at the casting then you will have to drill and re-tap.
Maybe time for a pro.


edit: Should mention that a pro may put a nut on the shaft then weld the nut to the stud to remove. So many ifs.
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Old 05-03-2020, 09:45 AM   #8
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Be t

Quote:
Originally Posted by Gloonge View Post
This guy has the easiest solution. Had not though of that, you can easily get 2 inches of clearance or better and everything should aide out whole.
Agree do this. Just did it to get to the rear drivers side spark plug. So easy. The others I did with out jacking. Next time I jack the engine, it took 7 min maybe to take lower cover off and jack it up. I prefer ramps rather than jack stands as you can lift the whole car a little in the beginning. Just safer on ramps IMHO.
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Old 05-03-2020, 11:04 AM   #9
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Quote:
Originally Posted by ls1ac View Post
Is the nut turning and not coming off? You can use a nut cracker to split the nut off or very carful use of a grinder. Then remove the pipe and then blast the stud, and remove with stud remover or perhaps Vice grips.
Do you mean that the nut sheered off the stud? Remove the pipe.
Then PB blast the stud that is exposed and then stud remover or try a vice grip. If it breaks at the casting then you will have to drill and re-tap.
So, there is a stud that is stuck between the overpipe and the headers. I didn't have a great camera but this is what it looks like if you can look closely

[IMG] https://drive.google.com/file/d/1u2t...ew?usp=sharing [/IMG]

Last edited by toughguy39; 05-03-2020 at 11:29 AM. Reason: explaining
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Old 05-03-2020, 11:12 AM   #10
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Quote:
Originally Posted by weederr33 View Post
Just unbolt your motor mounts and jack it up. Then you should be able to slip it out.
That's what I'm hoping to do just not sure if ill be able to take that out along with the headers attached.
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Old 05-03-2020, 02:53 PM   #11
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Yes, it looks like the nut froze and twisted the end off of the stud. When you get them apart then see above for removal.




edit: If getting it off becomes impossible with the broken stud stuck in the flange, you could use a hacksaw blade to cut the stud. NOT recommended because you might scar the flanges and have leaks and it will require drilling and using easy-out or retapping.
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Old 05-12-2020, 03:40 PM   #12
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I had almost the exact same thing happen. I was able to get a grinder in and just grind the hell out of it until it came apart. I only nicked the flange a little, should be able to press a new stud in and get it back together if I ever decide to go back.

It sucked. It was late, I needed the car to get to work on Monday (this was a Saturday night), and I was frustrated. I swore I would never tear apart my daily driver again. But since then, I've enjoyed the car immensely. Putting the headers on was the best thing I ever did to it. Good luck, whatever you manage to work out.
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