8 replies to this topic

[sh4ftmini]

Great forum, tried searching and decided to register to ask...

 

I'm replacing the exhaust (downpipe + Maniflow twin-box-catless exhaust) on my 1995 JDM Mini. I successfully removed the Downpipe and everything below the car, but one of the studs from the Exhaust Manifold to the Downpipe snapped off partially. All three are in poor condition, so I have three new studs to install.

 

My friend is bringing over screw removing drill bits, but before I do that, I just want to make sure that's the right move for replacing the studs. Or is there a nut on the top end of the Exhaust Manifold I need to get access to and remove?

 

I'd rather stay beneath the car and keep this project "easy" but I don't want to mess it up!

 

Thank you!

[xrocketengineer]

There is nothing on top, unless somebody got creative.  This is all you need:

 

http://www.minispare...px|Back to shop

 

I replaced all that on my 1994 Japanese Mini Cooper.

Welcome to the Forum.

[GraemeC]

I'd suggest spraying it with often with LOTS of penetrating fluid over the course of a couple of days before going near it with stud extractor bits.  If one of those snaps in there its potentially an expensive removal process or replace the manifold.

 

Personally I'd be taking the manifold off and using lots of heat to get the rust to release its grip.  Welding a nut to what remains of the stud might to the job.

[nicklouse]

by the way easy is remove the manifold.

 

I bet you will end up doing so anyway.

[FlyingScot]

Plus 2 for removing the manifold. Forget trying to do it in situ..... the good thing if it all goes wrong you can still get new ones

 

plenty liquid wrench on

 

FS

[sh4ftmini]

I bought the replacement studs. One appears to be longer, hopefully that’s normal? Removing the manifold looks like a ton of work... I just got my new exhaust, a maniflow catless one that was supposed to fit the stock mounting points but doesn’t have the posts for the rubber mounts ‍♂

[MatthewsDad]

It's not too bad a job. If you have a Haynes manual it is pretty well described.

[xrocketengineer]

Make sure to replace the gasket and the nuts too. Mine was running rich because of a leak at the gasket right next to the O2 sensor. The new gasket with sealer solved the problem. When tightening the nuts, you have to drive each one a bit at a time for a good seal on the flange.

The old type bolt on exhaust mounts fit your subframe, you need to get those to install your new exhaust system. That is what I was doing on mine but for some reason, they sent me metric bolts. The subframe threaded holes are not metric.

Edited by xrocketengineer, 09 November 2020 - 09:02 PM.

[sh4ftmini]

Stud extractor did the job. Had to do a few trips to the hardware store, but not totally crazy. New exhaust is fitted. Taking it for a spin tomorrow.