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Re: Engine Problems

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Posted by Steve on February 01, 2003 at 23:47:08:

In Reply to: Posted by on February 01, 2003 at 20:50:57:

: A few weeks ago I began having engine problems.

: Today me and my dad were going to try pulling the manifold, the exhaust, the carb and then the head.

: One of the bolts on the exhaust manifold was already broke off..for I dont know how long. But then today we snapped the bolt the farthest to the front. My dad said it will have to be machined, and if we have to pull the motor to take it to a machinist, I might as well have it rebuilt.

: Northstar Willys has rebuild kits for $425 I believe. A friend of my dads knows a machinist who will rebuild motors and is supposeddly pretty good. My dad said he will try to get over there on monday to ask about it. Around how much should I be expecting the rebuild to cost?

: We ended up having to cut the exhaust off, because one bolt is snapped and the other one is rusted on there. Had to use the dremel to get that one off. No matter there, because I have my new complete exhaust system in my room, but we still need to get the manifold off.

: Just felt like sharing my dilemma,
: Denny

Denny-

Pulling the engine and rebuilding it is a bit extreme, unless there are much deeper concerns than the broken manifold bolts.

I too had two broken studs, but was able to fix them in the Jeep. I DON'T recommend trying an ez-out on the manifold studs, because the extreme temperatures involved during normal use tend to gall the studs into the block; If you break off an ez-out you are royally screwed because you cannot drill it out. Period.

Just remove the manifold, and cut the stud off even with the block if it isn't already. Use your dremel or a die grinder with a round-headed abrasive grinding head to slightly indent the stud into the block. You can then use a center punch to mark the stud and re-drill it. An air drill works well here, but a good electric drill will work too. Use a tiny bit first, and try to drill as straight as you can into the stud.
Finish with a 5/16 drill bit and tap with a 3/8-16 tap.

If you drilled correctly, nobody will be any the wiser, and it will work like a charm!

Steve in Pittsburgh


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