So today I got my Z on a lift to change the exhaust and I got all the nuts and bolts out fine, except for 2 on the 02 elbow. I tried it all...breaker bar ,PB blaster, torch..nothing would do it so I used an impact gun and the studs broke.

Is there an easy way to get them out? I tried an easy out but it broke Any ideas on what to do?? I need to drive the car everyday and cant have it sounding like a jet plane.

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1984 Z31 Turbo

There are several ways to remove broken studs, depending on how much room you have to access them. I'm unfamiliar with the O2 sensor on the Z31 or Z32 cars ~ do you have a photo?

Usually, depends on whether the broken stud is protruding above a surface, or below it. If you've already used an EZ Out, I guess you now have a hole in the stud?

When I was a kid I knew a guy who used to buy cheap box-end wrenches for such emergencies. He would find a 'good' size wrench and nut, and weld them both onto the top of the broken stud. Then when it cooled, he'd tap it all around with a hammer while turning it off.

Here's a modern variation of what he did back in 1965:

http://www.youtube.com/watch?v=bSOg7aQ44eg&feature=fvst

There are other ideas in the sideboard if you can't use this one.

Frank

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1970 240Z

They are above the surface. Couldn't get them with vise grips either. I drilled a hole for the easy out in one of the studs but now its broken in it I could take off the elbow and drill them out but Im trying to avoid having my baby out of service. Heres what the elbow looks like

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1984 Z31 Turbo

AHA! So you can immobilize this in a vice, or mobilize it to a shop for them to work on ~ excellent.

After soaking with penetrating oil or PB Blaster or some other wonder drug, I have sometimes cut a slice across the stud and inserted a common blade screwdriver. Using a vicegrip on the screwdriver for leverage (and putting my weight down onto the screwdriver to hold it in the slot) I have been able to 'unscrew' many bolts.

Sometimes that doesn't work, and I only distort the stud. Then the welding-on-nuthead works best. Or you can take it to a machine shop or garage and have them remove it for $10. They do that all day long, every workday. It's a common evil in the life of a mechanic and some of them have their own favorite way to remove stuff. Drop it off to them and don't worry about how they're getting it out ~ it's not your problem. In the 20 minutes it takes them to remove it for you, you should be at your local Nissan dealer buying the correct replacement bolt/stud. In fact, the Nissan place would probably be the best place to take it in the first place.



Frank

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1970 240Z

Thanks for the advice Frank I"ll definitely be using that welding on the nut technique if I...or should I say when I break another bolt. But since its in a tricky spot i will bring it to my local Nissan tomorrow and let the wizards work their magic.

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1984 Z31 Turbo

Yup ~ best idea. Mechanics do that for a living, anyway.

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1970 240Z

All sorted out 7 hours and $200 the studs where out.

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1984 Z31 Turbo

$200!!??? Ye Gads! Where did you take it? (I guess you had them remove all of them, huh?)

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1970 240Z

A friend suggested Monroe in Manchester...took them 2 hours to get the car in the garage where it sat for another hour before anything was done. They only removed the 2 broken studs. GREAT way to spend a Saturday Better believe I had a word with my buddy.

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1984 Z31 Turbo

Well, I can understand a muffler shop waiting 30 minutes to let the exhaust cool off, but 3hrs seems excessive.
I have used Monroe Muffler ONCE in my lifetime ~ here in CT ~ and my experience was so bad I have never returned to them for anything.

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1970 240Z

Darn, too late, but $50 would of been my charge. Beer and Pizza always works too.

I'll remember this...

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Justin
1986 Z31 NA 2+0

Right, Justin ~ and the conversation would have been more fun, too!

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1970 240Z

I would have just asked for Pizza and Beer. With my Oxy/Acet. torches, there are no Boundaries. There's one thing fixing cars, but being an actual metal worker comes in handy. Next time, keep me in mind.