2016 4Runner spark plug replacement - broke emission tube stud
Decided to change the plugs today with 104k on it, and didn’t have any issues on passenger side in removing the emission valve and tube from exhaust.
When doing the driver side, the stud from the exhaust manifold snapped…crap. I tried removing but not enough to grab, and also tried drilling it out, but no room to work and unable to drill as stub is slanted and could center punch…bit just wandered. I finished the job, but now I only have one stud/nut for the driver side air tube. I used new gaskets and didn’t see any issues or hear a leak when starting it up. I used a metal zip tie on the unclamped side to help clamp down that side a bit. Trying to determine how to move forward. As the tube is in place, I was thinking of obtaining a left hand drill bit and try drilling it out or all the way through as the tube flange can in theory keep the bit in place in the limited space. |
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5th Gen 2014+ Spark Plug Removal (Air Injection Pump) |
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As I noted in my original post, I tried drilling the stud, but keeps wandering off as it’s at a slant and I can’t center punch it / drill. I wanted to use a left hand bit, but they don’t come in a hex shank…I have to use a long extension on the drill. The jobs a bit harder than expected with limited room to get in there…if it was passenger side, it would have been much easier. I may see if I can get in there to grind down the stud a bit to flatten it, then trying to center punch again and drill. |
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I mentioned use of a long drill extension as a workaround, but can’t with current state of stud so I need to see how to grind/flatten the jagged portion of the stud before trying again with a long bit extension. |
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Should be able to weld a nut on to the stud and get it out. |
I did the same thing. I just bought one of these clamps from McMaster, milled a slot to clear the broken stud (you could grind, or even file this in). It's been in for over a year now, and works just fine. At 200k, I'll take everything apart and fix it for real. I'll take some pics tonight.
McMaster-Carr |
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Been busy with life, but purchased a right angle drill adapter from Harbor Freight that may enable me to drill with a left twist bit. All of the 10” - 12” drill extensions only seem available for hex shank bits which only work with regular bits…havnt found left twist bits in a hex shank. I’m attempting to go that route as I would like to keep those threads, but may just have to drill through and use a bolt / nut. I still have to get in there and cut off the broken stud to flatten (jagged stud) it so I can drill. It’s a pain working in that limited space on the drivers side though. |
Dremel with a cut off wheel should get in there.
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