exhaust header headache

[lmbma]

Anyone know of a quick way to take off a passenger side exhaust header that is rusted bad. I have tried to take it off myself but my job loaded me with overtime so I handed it off to a mechanic. After 2 days with it he gave up and since then no other mechanic will touch it. So any ideas are appreciated.

 

[FordandPolaris]

If I were you, I would find an exhaust shop around the area. They should be able to remove it, though it will not be cheap. It is very difficult to do by yourself, especially if you have broken studs. If they are broken into the block, you need to be able to weld a nut onto the stud that is inside the block. I do have a write-up on how to do it on an F-250, which is essentially the same if you want it. Its just something i found in the internet a few months ago and decided to hang onto, but its a PDF. PM me an email address and I can send it to you.

 

[Thermo]

Imbma, plan on about 4-5 hours of labor. A bit more if they have to deal with broken studs (which is a high likelihood). I removed the headers off of my truck and I broke 3 studs. I was fortunate though in that they broke right at the nut. So, I still had about a half inch of stud sticking out which allowed me to squirt it with some penetrating fluid and then use a set of vice grips to pull the rest of the stud out. From there, I bought new fasteners (went with high strength capscrews) and fixed the problem myself.

 

[toms89]

Pull off the tire and inner fender liner. You will have very good access then. The studs are known to rust and break off creating an exhaust leak. As thermo said if they break at the nut you can try and remove the rest of the stud after the exhaust manifold is removed. Use plenty of penetrating oil and let it soak in. The heads are aluminum and have heard many had luck removing the broken studs easily after the manifold is removed.