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Old 11-23-2003, 07:25 PM   #43
Airstream Driver
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1997 30' Excella
Austin , Texas
Join Date: Feb 2002
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Originally posted by AccessMaster
After reading all of the prior posts I still have a basic question.
One of the 3 bolts that hold the exhaust flange to the manifold on the drivers side has broken off. I now have a leak that is very noticable when cold and not so bad when hot. How big a project is it to get the flange tighten up again? Since the bolt is broken off am I now looking at removing the manifold etc....
My experience with a broker stud exhaust manifold, unless it's not broken flush and they can weld a nut on it to remove the broken stud.
I use big brass nuts to keep them from freezing up.

1996 Airstream B190
1987 29' Sovereign Trailer
1997 30' Excella Trailer
AIR #13
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Old 11-24-2003, 11:49 AM   #44
Rivet Master
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1978 31' Sovereign
Texas Airstream Harbor , Zavalla, in the Deep East Texas Piney Woods on Lake Sam Rayburn
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Access Master

I'm going to chime in here.

I have a different interpretation of which bolts you're talking about.

I believe the bolts you are referring to are the bolts that hold the first section of the tail pipe to the tail pipe end of the manifold.

All these are a little different. On my '87, with the "factory headers" (welded manifold with an expansion joint between the front pair and rear pair of cylinders) the bolts (actually studs) on the drivers side are longer than the curb side due to the fact that the vacuum controled exhaust valve is sandwiched between the manifold and the tailpipe (this device encourages quick engine heating).

Since you probably have fuel injection on your '88, you may not have this valve.

I started to drop the valve out so I could inspect the internals, but the first stud I attacked took an internal twist, did not break loose, but did not torque off. Rather than have to drill the stud out (or worse), I just left it alone.

The good news is that there is enough room to work in the area without having to take off too many accessories.

The curb side is a little tighter, due to the proximity of the starter.

Bottom line is, from my observation, hoping to remove only the studs is wishful thinking. Plan on the studs torqueing off befor they back out.

If you do try to back them out, conjur up a lot of patience.

Heat, heat, heat, tap, tap, tap, soak, soak, soak.

Like the signature lines of one of the forum members, a quote from Mr. Turbo and Bog Frog.

"If you get it REAL hot, and hit it REAL hard, somethin' has GOT to give.

Good Luck.


"Suck it up, spend the bucks, do it right the first time."

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Trailer '78 31' Sovereign

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Old 11-30-2003, 09:23 AM   #45
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Join Date: Apr 2003
Posts: 119
454 Exhaust Repair Tip (Must Read)

You gota love it when something goes right. My 1988 454 developed an exhaust leak as a result of a broken bolt at the exhaust manifold / pipe connection. After talking to an old timer who is still working on exhaust systems he verified that a clamp is made specifically to replace broken studs that hold the exhaust pipe to the manifold. There are 3 bolts that hold two flanges together with a gasket in between. When these bolts break there is a low cost alternative to spending, or paying to have someone spend, hours trying to remove and replace the broken stud and the others that are sure to follow when the repair is attempted.
The name of the part is "Clamp a Stud". It is manufactured by Nickson Industries, Inc. - Plainville, CT. I got mine at O'Riely Autoparts. It is in their computer. I was really lucky that my local store had a set of these on the overstock / discontinued shelf in the back. There are 4 different parts depending on the size you need. I needed Model 501. It looks like it would work in all cases. Parts 500, 501, 502, 503 are available.
This is a "C" Clamp that fits into the indention on the top of the broken stud and thru the hole in the bottom flange for perfect alignment and fit.
My cost was $15.00.
Amazingly the clamp worked perfectly. It was easy to put on and stopped the exhaust leak.
After all of the help I have received from the forum members, I am glad to be able to add this money saver to our data base of solutions to difficult problems.
Keep on Streamin'

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