Help! I'm Stuck - Removing Gti6 Manifold

[Masekwm 2]

So, I decided to finish the conversion properly with a Miles manifold. From underneath it was clear that I was rounding a nut, so out came the engine.

 

With the engine out, one nut is clearly damaged so I decide to leave it until last. 6 of the 8 nuts off, I move onto the 7th, I note the manifold is close but figure it'll be fine. Wrong! The stud comes out with the nut and the ratchet is now stuck against the manifold, although the ratchet is now on tighten, the stud won't line up so won't go in.

 

The only way to free the ratchet is to get the knackered nut off.

 

So far I've tried smacking on smaller sockets, mole grips, plus gas, filing it to smaller, nut splitters and although it's getting smaller it's still holding the manifold on. I think the ratchet is putting pressure on the nut and so I'm battling against the pressure as well as the nut.

 

I'm stuck. Any tips? Do I need heat? What other tool can get this nut off, it needs to be deep as the stud is quite long.

[Anthony 1,003]

Can you not just remove the other remaining nuts and remove the old manifold with the stud still attached? Then just replace it with a new one to refit the new manifold, and with the old manifold removed from the head and the stud able to move freely, you should be able to take off the ratchet no problem.

[Masekwm 2]

The ratchet is pinned between the manifold and part of the manifold that attaches to the head by the stud that has released itself.

 

The damaged nut is holding it all still together, I can't get the stud to come out either which would be just as good at the moment.

 

On the left looking at the engine, there is a good 0.75cm clearance and on the right it's held tight.

 

It's a bit of a f*** up.

[Anthony 1,003]

What I mean is, can't you leave the ratchet where it is for a moment, remove the 8th manifold bolt, and then take the manifold off complete with ratchet/stud? Once the manifold is off the car, you can push the stud back through the hole, giving you sufficient clearance to take the ratchet off.

[gowmonster 2]

angle.......grinder.

[cheesegrater 43 1 Cars]

Can you not get a hack saw blade and cut the stud? I'm struggling to picture what you've done

[Masekwm 2]

What I mean is, can't you leave the ratchet where it is for a moment, remove the 8th manifold bolt, and then take the manifold off complete with ratchet/stud? Once the manifold is off the car, you can push the stud back through the hole, giving you sufficient clearance to take the ratchet off.

 

Ah, yes, that is my cunning plan.

 

Ruined by the knackered bolt that won't budge.

 

Perhaps I need some heat?

 

Can you not get a hack saw blade and cut the stud? I'm struggling to picture what you've done

 

Tried that tonight, going to buy a better hacksaw and try again. As removing the bolt, should release the tension and release the broken bolt.

 

I think this is correct.

 

 

Angle grinder - I'd love one, but I have no power in the lock up.

[Anthony 1,003]

Apologies, I thought it was the same nut that was stuck on the ratchet I understand the issue you're having now.

 

Have you tried hammering a 6-sided socket over the nut, or if you have some (and they're very, very useful for things like this if you haven't) using a nut/bolt extractor on the remains? Other thing is to put the studs/nuts surrounding the rounded/stuck on back in and do them up to relieve some of the tension on the rounded nut, although I'm not sure how effective that will be as you're unlikely to bend with the manifold flange or the jammed stud.

 

Other option is if the engine is out of the car already, is there any way that you could transport/move the engine to somewhere that has power so you can take a grinder to the stud and/or rounded nut?

[Tom Fenton 1,542]

Irwin Nutgrips, these are the answer to your problems, excellent things.

 

[welshpug 1,657]

as above, that's what I used on my J4RS's rounded nuts

[Masekwm 2]

Another person recommended them and I've just found Screwfix sell them far less than eBay.

 

I'll pick up a set on Friday and hope that I've not either knackered the nut too much or they aren't deep enough.

[welshpug 1,657]

they have a hole all the way through, so if you use a spanner or a socket rather than fitting directly to a 3/8 ratchet you will have a little extra depth to play with.

[Masekwm 2]

Thanks guys

 

I'll update if I get the buggar off.

[Tom Fenton 1,542]

They are the kind of tool that you will not need often, but when you do need them, nothing else will do. I bought the base set and the expansion set, money well spent!

[Jrod 7]

They have never failed me, locking wheel bolts, allen key heads etc. Awesome tool.

[Masekwm 2]

Screwfix were still open when I got home so I popped down. Five minutes it took to free the nut and it brought the knackered stud with it too.

 

 

And I've got my ratchet back

 

Thanks all.