You really need to get it fixed. Having an exhaust leak at the head will
result in a warped-burned valve. The leak will also confuse the O2
sensor and burn a path in the header flange and head. The header will
need to be removed and the stud dealt with.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Wesley Alden Pegden
Sent: Friday, June 24, 2005 7:27 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Oh no. Exhaust stud breakage.

My worst fears come true...
A few weeks ago, I installed a new exhaust system.  Without a torch, I
paid someone to remove the studs for me.  He removed two, and said he
pulled pretty hard on the other two and they wouldn't budge, and was
afraid they were going to break, and so left them in.

A week or so ago (after I had the new system on), it seemed like stuff
was pretty loud, so I checked the bolts on the exhaust.  Sure enough,
one of the stud nuts (the top nut on the front passenger side), wasn't
down all the way.  I went to tighten it down, and the stud twisted right
off.

It's broken off right at the end of the hole in the header (so it still
holds the header in place).

My question is: what can I do?  An attempt at removing the stud, it
seems, will almost certainly meet with the same sad fate as my attempt
to turn the nut all the way on.  I certainly don't think I have the
means to drill the stud out right now (or have it drilled out).  Do I
have any other options, other than driving aroud a loud van (and failing
PA inspection in August)?

Thanks for any help,
Wes