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Thread: Exhaust manifold stud broken

  1. #1

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    Atlanta,GA
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    1993 Mitsubishi Mighty Max
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    4G64

    Exhaust manifold stud broken

    Hi all,

    I got a 1993 mighty max with 8-valve 4G64 engine. Vehicle has 190k miles. Currently I discovered the exhaust manifold studs are broken, the first one and the last one. Good thing is the remaining stud is still above the surface. Questions are:

    1. How to do stud extraction? What kind of special are helpful?
    2. Can I do stud extraction without taking of the head? Looks like there is plenty space if I take off exhaust manifold. Anybody ran into similar situation?
    3. Where can i get high quality exhaust studs? I don't want this happen to me agian.
    4. If I don't want to fix it now, what is the risk? The whole exhaust manifold fall off? I only use this truck as a spare vehicle. Very trip is short distance, usually less than 1 hour. I am thinking of rebuilding engine in 1-2 years. So if I can keep it the way it is now, that would be great.
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  2. #2

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    Adelaide, South Australia
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    1985 Mitsubishi L200
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    G63B
    If there is still some of the shank exposed after taking the whole manifold off you might be able to get enough of a hold on it with a pair of locking jaw pliers and undo them. If you don't replace them the worst thing that will happen is an exhaust leak from the manifold. It will run like a pig but it'll run. An as for replacing them just go to a junk yard and pilfer a few off any engine with the same pitch thread (they're metric so pick something out of the same family - DSM, Hyundai, Kia, Mitsubishi etc)

  3. #3

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    Richmond, CA
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    1989 Mitsubishi Mighty Max
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    That last stud breaks pretty often. I've had pretty good luck with these, but screw and bolt extractors generally all suck.

    Click image for larger version. 

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    There's also the welded nut method:

    https://www.facebook.com/SpeedSociet...6232607727372/

    There are a few bags of OEM studs on eBay right now:

    http://www.ebay.com/itm/New-Nos-Oem-...tUvmZ7&vxp=mtr

    http://www.ebay.com/itm/Mitsubishi-M...pSO0Le&vxp=mtr
    I can help get your truck to pass California smog! PM me.
    California BAR Smog Inspector License #EO635469
    "Keep 'em on the road."

    See what I have for sale:
    http://stores.ebay.com/zims

  4. #4



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    Pittsburgh, PA
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    1980 Dodge D-50
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    G54B
    you can also use a socket made for rounded nuts if you can find one small enough to bite the shaft.
    Pennyman1
    The best Dodge that Dodge never made
    Living the D-50 lifestyle since 1980

  5. #5


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    Columbus, OH
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    1992 Mitsubishi Mighty Max
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    Replacement studs can usually be found at a good hardware store, no need to go junkyard hunting for them. you can do it on the truck. I replaced all of mine on the last re-build, not a hard job...

  6. #6

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    1987 Dodge Ram 50
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    G63B
    What is the correct size for the exhaust manifold studs?

    8x1.25x ??????....I need to know the correct length in order to get replacements and I can't seem to find anything definitive.

    Sorry to bump an old thread but I've asked in the Facebook page with no response.....

  7. #7


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    Well I spun out one of the good one's and went to the Hardware Store and did a Stare & Compare. I also picked up fresh nuts.

  8. #8

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    1987 Dodge Ram 50
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    That was my plan, but it seems that I can only get the broken one out ( go figure) ....so I'm gonna have to guess a bit.

    I do know it's not 55/56 mm as I've already ruled those out....going to give it another go today and see if I can find the right one.

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