changing front flexi exhaust section

[elty001]

my front flexi section has been blowing for a while now.i did a bodge repair on it a few weeks back but I go on holiday next week and thought I best get it sorted.
started the job yesterday afternoon.all was going well,removed the front prop to give me a bit more room to get at the bolts.soaked the bolts in penetrating oil for a couple of hours before I started but as soon as I put the socket on and gave it some pressure it sheared.:doh:doh:doh
had a look at the damage and as far as I can see I need to remove the elbow off the back of the turbo and drill it out.how big a job is this and has anyone got any pointers before I start.

 

[TONUP]

If I remember correctly there are three bolts connecting it to the exhaust manifold.

Is it the one against the engine that has sheared, and how much of the bolt is hanging out?

This happened to me when I changed mine, and I used a stud extractor to remove the remaining part of the stud, which is screwed in, then replaced it with a nut & bolt.

Regards

Alan

 

[elty001]

the one that's sheared on mine is the furthest away from the engine.
its sheared level with the flange on the exhaust so I would say about 10mm of the bolt is left.
not touched the other 2 yet as I had to leave the car in a usable condition for the mrs.

 

[Nav230]

If you have access to a welder, you can weld a blob on the end of the broken stud, put a nut over the blob then weld the nut to it all. The heat helps free the broken stud too. It sometimes takes a few goes to get a good weld but it's a tried and tested method I've used for many years.

 

[elty001]

cheers for the advise.
not looking forward to getting the socket on the other 2 as they look even more corroded than the one that's sheared off.
will go for a bit of a run then try and crack them when its nice and hot.
if I can get the welder up in the gap I will weld a nut on the end of the broken stud.that way I haven't got to start stripping off the turbo as there is not enough clearance between the bulk head and the studs to get the elbow section of the manifold off.
all great fun and its give out thunderstorms later when I get home from work.

 

[TONUP]

I think that you could get a small drill onto it from through the wheel arch if you get the front nice and high, so the suspension drops out of the way.

Good luck.

Regards

Alan

 

[elty001]

I think that you could get a small drill onto it from through the wheel arch if you get the front nice and high, so the suspension drops out of the way.

Good luck.

Regards

Alan

have got a small air drill I might be able to get in with:thumb2
forgot about that.
will see what prevails later.

 

[vince]

i fcound it easier just to remove it and do bthe work on the bench. but if you do be carfull when u fasten the turbo coolant pipes to the engine as they are f#@kers to get to. good luck

 

[darryl]

my front flexi section has been blowing for a while now.i did a bodge repair on it a few weeks back but I go on holiday next week and thought I best get it sorted.
started the job yesterday afternoon.all was going well,removed the front prop to give me a bit more room to get at the bolts.soaked the bolts in penetrating oil for a couple of hours before I started but as soon as I put the socket on and gave it some pressure it sheared.:doh:doh:doh
had a look at the damage and as far as I can see I need to remove the elbow off the back of the turbo and drill it out.how big a job is this and has anyone got any pointers before I start.

hi smack the remaining stud with center punch so the drill can locate otherwise it will spin all over the place

 

[elty001]

all sorted now:thumb2
the little air drill I have got worked a treat.shame that the compressor only had enough guts to last about 30 seconds at a time but it got there in the end.
the other 2 nuts came off eventually.went for a run before I started so everything was nice and hot.
just got the front prop to fit back on later when I get home from work.
didn't realise how bad the flexi was until it came off.dont think it would have lasted much longer.
thanks for all your input.
:bow:bow:bow:bow:bow:bow