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Broken exhaust manifold stud

mirchandise

Passed Driver's Ed
So like a few others on here, the drivers side exhaust manifold stud broke and the manifold is warped. My car has about 80k miles and has been stage 2 since 50k. The shop says that stud broke in such a way that just a little bit of it is stuck recessed in its hole and would be nearly impossible to drill out. They want to pull the head and send it to a machine shop to have them extract it and then put everything back together, with a K04 instead of the K03 (only a $500 difference). All together the estimate is at $7k. I honestly don't know what to do. I'm not sure what I could get for the car in its current state, but KBB puts my GTI between 7-9k if it was working. I read about this on another thread here and someone mentioned finding a specialist bolt extractor - does anyone know of one in the Bay Area? I think what I want to do is try everything before pulling the head.

Sorry for the ramblings. If anyone has any advice or suggestions please let me know!

Thanks.
 

MrFancypants

Autocross Newbie
$7000..... I guess about $3000 of that is the cost of the K04 as well as install labor.

$3500 to $4000 to get at a broken stud sounds extremely high. I know it’s in a difficult spot but surely there’s someone, or even a shop near you that specializes in bolt extraction that can get to it for less.
 

mirchandise

Passed Driver's Ed
$7000..... I guess about $3000 of that is the cost of the K04 as well as install labor.

$3500 to $4000 to get at a broken stud sounds extremely high. I know it’s in a difficult spot but surely there’s someone, or even a shop near you that specializes in bolt extraction that can get to it for less.
It’s about 3500 for labor, including the machine shop and then another 3500 for the parts, including all the head stuff and K04. I’ve been looking for a specialist but I haven’t been able to find anyone yet unfortunately.
 

zrickety

The Fixer
LOLOL You can pull the manifold and drill out the stud yourself. Helicoil under $20.
I just did 3 of them on my Mini Cooper project.
Edit- when you pull the manifold, make sure you only loosen the top bolts...the bottom ones are for position and you'll be using a mirror to put them back where they belong. Ask me how I know.
 

zrickety

The Fixer

GolNat

Autocross Champion
Reach out on social media if you have it. There is probably a guy or gale that has experience with it.
 

zrickety

The Fixer
I've pulled and installed the exhaust manifold without removing the head. If you want to remove it, go ahead but it's unnecessary. The hardest part of all this is disconnecting the oil and coolant lines from the turbo. You're making this harder than it has to be.

LOL this guy breaks a bolt at 80k and it becomes an engine swap. You guys are hilarious.
 
Last edited:

jay745

track sl00t
I've pulled and installed the exhaust manifold without removing the head. If you want to remove it, go ahead but it's unnecessary. The hardest part of all this is disconnecting the oil and coolant lines from the turbo. You're making this harder than it has to be.

LOL this guy breaks a bolt at 80k and it becomes an engine swap. You guys are hilarious.
^ a broken stud isn't the end of the world at all. I was just saying for comparison sake that $7k is ridiculous. I've swapped an engine in for someone for $2k total that included the used engine we found.
 

zrickety

The Fixer
That's a killer deal. I'd like to know who pays $7k to fix a stud. I'm in the wrong line of work.
$2k you could almost get me on a plane to Cali and I'll buy the tools when I get there. Almost.
 

mirchandise

Passed Driver's Ed
^ a broken stud isn't the end of the world at all. I was just saying for comparison sake that $7k is ridiculous. I've swapped an engine in for someone for $2k total that included the used engine we found.
That’s what’s killing me. $7k to get a broken stud and replace the turbofold But like I said all the shops I’ve called said that they would want to pull the head to get at it. I’m trying to find a shop or someone that would be willing to try and drill it out. But at this point I think I just want to be done with the car.
 
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