Written by Garbacho

Description:

This is the procedure for extracting and replacing broken manifold studs on the passenger side of a VG30 engine.

If you havn't worked with an extractor, it's pretty easy. They come in different sizes (the size you use depends on the size of the broken bolt or stud in this case) and they kind of look like drill bits. You can buy them at auto parts stores or Harbour Freight.

Tools Required:
• extractor
• a drill
• a new gasket
• new studs

Procedure:
• Remove wheel and wheel well liner
• Unbolt manifold. It might be easier to remove stubborn bolts if the motor is warm.
• I found that the biggest pain in the ass is getting the manifold out of the way without unbolting it from the exhaust down pipe but it can be done. Pull manifold off of studs and out of the way.
• At this point, you can decide if you want to replace all the studs or just the boken one. I'll assume we're just removing the broken part.
• Now for the fun. Using the appropriate drill bit size (it says what size to use on the extractor package) CAREFULLY drill into the center of the broken stud. You only need to go in 1/4" to 1/2" MAX. Gently hammer the extractor into the drilled hole, grab the end with vice grips or any other appropriate tool and "unscrew". If a stud is being stubborn, take it slow and work it out slowly. "Unscrew" until it binds then screw in again, keep repeating this, forcing it a little furhter with each unscrew. Take your time beacuse if you break the extractor in the stud, you'll have a hell of alot more work to do.
• Replace broken stud and be sure to use a thread lock of some sort, nothing too aggressive though just in case you have to do this again in the future.
• Replace gasket and reassemble.
• IMPORTANT: Refer to shop manual for the propper bolt tightening sequence.
• Drink a beer and pat yourself on the back.

*Note: I've only done this on the passenger side of my 95 XEV6 Hardbody 4x4. I' ve heard that the driver side is harder to get to but I'm not positive.