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Sat Nov 07, 2009 6:42 am

Got a 74"SB with a stock exhaust set up. Its been running a bit louder and popping so I sheck the exhaust and found that my drivers side exhaust port on the #4 cyl has the top stud broken off flush and now have a 1/4" gap between it and the flange on the muffler. Am i"m correct saying the threaded stud is not removable or cannot be unthreaded from the exhaust port and replaced? Either way I know the motor would have to be dropped to fix this but tring to find a way around this. What about tig welding on a threaded stud over the broken one? Thx

Sat Nov 07, 2009 7:05 am

It won't be easy to remove a stud from a head, and you'd definitely have to add heat, but some have reported removing broken cylinder head studs. On mine, I just drilled and re-tapped for 8 x 1.25mm and purchased new studs, and I now use special brass nuts on these that use a smaller wrench size. I took off my exhaust (be careful not to break any more studs), lowered the engine and drilled it while it was on the jack still underneath my bug.

As to welding, if one can weld on a stud without doing any damage, that should work.

Sat Nov 07, 2009 8:33 am

You can also drill it out and put in a helicoil and use a bolt instead. If you run it like it is you WILL burn a valve.

Sat Nov 07, 2009 12:05 pm

sturgeongeneral wrote: You can also drill it out and put in a helicoil and use a bolt instead. If you run it like it is you WILL burn a valve.

i had to put helicoils in all 8 exhaust studs...

Sat Nov 07, 2009 12:15 pm

hey exjay, is that as in XJ Cherokee? Just a guess. Anyway like the others said, however you choose to repair it, do so and soon, burnt valves are not fun when they can be avoided fairly easily.

Sat Nov 07, 2009 3:23 pm

MoparFreak69 wrote: hey exjay, is that as in XJ Cherokee? Just a guess. Anyway like the others said, however you choose to repair it, do so and soon, burnt valves are not fun when they can be avoided fairly easily.

Actually yes. I use to have a lifted 90 Jeep XJ and a 2000 sport and was on the Jeepsunlimited forum a bit (kinda stuck) I would have loved to kept them but when you have kids etc to start putting in them you run out of room pretty quick. I will have another one day, oh yes.....I will (and a fixed exhaust leak too!)