While I was swapping out my bellmouth downpipe this weekend to put the stock downpipe back in, I managed to break one of the turbo studs. There is about 3/8" of the stud left. I managed to put the stock downpipe back on, and because the flange on the stock DP is thinner, the broken stud still comes through just a bit, but because as of now, there is no nut on it (don't even know if it will work, since the stud didn't break off entirely clean). The car runs ok, no audible leaks, etc., but it's bugging me, and I want get it fixed. So, here are my options:

1. While the turbo is still in the car, and downpipe removed, I MAY be able to try to clamp the broken end of the stud with some vice grips and try to uncrew it/remove it.

2. If option 1 doesn't work, I can pull the turbo and do the same thing - might be able to get some more leverage on it that way.

3. Remove the turbo and take it to a shop to fix - would like not to have to do this.

4. Just buy a new td04, and replace the turbo with one that has functioning studs. My current turbo has about 70k on it, and it SEEMS to be fine, but you never know.

What would you guys recommend?

 

uhm if you still have enough metal for a locking clamp then you migth be able to get it off. spray some pb blaster onto the stud. if that doesnt work then try to sand down 2 of the side to make it flat so you can put a wrench or use it to help the locking clamps hold better. if not then take off the turbo and do it.

 

I have a set of brand new turbo studs if you're interested.

 

Sounds like you have enough stud sticking out with the dp off to use a bolt extractor.

 

Bill...sounds like its time to upgrade to a VFxx

 

Don't know who Bill is, but I WAS toying with the idea of upgrading, but given that my engine has 145k on it, it may not be the best time to do that right now. At this point, my car is a daily driver/commuter, and I really need it to be reliable more than anything else.

 

I had cross threaded one of those studs. I took off the turbo and used a vice grip to remove the stud. Went to my local hardware store since the stealership was not open and bought a new stud.

 

I see. I think I may end up doing this, although I was hoping to not remove the turbo.

 

Well if there is enough room to get it out you won't have to