Another Downpipe issue

Today I was replacing the gasket for my downpipe on my GP (99 Gtp, 107k). When I went to bolt it back on, one of the studs snapped and I've noticed the second is stripped.:banghead:

Can these studs be removed and replaced? If so would anyone have a part number or tip on the job? If not what all has to be replaced to be able to bolt the downpipe back in? Thanks in advance for the help.

I had the same issue with mine so I just took it to a shop. To get the stud back in I suggest you re-tap the hole. Unfortunately I don't know the thread size or stud size, but I just went to the dealer to get mine, asked for it and they found it on a diagram. It's cheap too, only like a buck or so. You will need 2 new studs to bolt the DP to the rear manifold, and a couple new nuts as well.

Retap the hole, drive the stud in. Place gasket between downpipe and exhaust manifold and mount...run the nuts on the studs and tighten (I don't know the torque...I'd say hand tight plus some torque from a regular 3/8 wrench, just don't overdo it). You can add RTV between the manifold and DP in addition to the gasket, just don't get it on your o2 sensor.

For what it's worth, it looks a LOT easier to do while the car is on a lift, or at least ramps....it was a pain the ass to try it with the car on small jackstands.

If this is a 3" DP I've heard it's good to flip the sway bar so it faces the other direction otherwise the pipe can hit it and cause false knock.

Thanks for the info! I'm going to take it to Midas which is around the corner from my house to have them take a look and give me a quote. Unless they want some insane amount for it I'll more than likely let them do it. The ramps i've been using make it a PITA just to get to the downpipe. I'll post tomorrow when they give me the quote to give an update. Thanks again.

Honestly, don't expect it to be cheap...

When I took it into the exhaust shop it cost me 200 bucks...he had to run out to grab a tap, tap it, replace the pipe...then weld it because the bolts on the resonator to DP wouldn't break loose...

This kinda work can get costly...when you run into problems while doing custom.

Honestly, don't take it to Midas...I've heard bad stories about that place...find a muffler shop close by and take it there (I drove with open headers for a few days...don't worry about it :P) At least with a muffler shop, if something gets screwed they can always weld...I don't know if Midas does any welding, just direct replacement.

Did they use a acetylene torch on the bolts. I have never had a problem getting stuck bolts out, when using a torch on them. You are correct about Midas, they will not do any modifications, they will just replace and that is it.

I should have mentioned that the downpipe is the 2.5" pipe from ZZP not the 3". Midas is going to replace the studs and bolt the downpipe back in with a new gasket for $200. I'm not a big fan of taking my car there, however the price was fair and I was able to drive the car to the shop. The lowest quote I got was $160, but the car would have needed towing to get 30 miles across town. I'll pick the car up later today or tomorrow and let you know how they did. Thanks again for the help, the price was right on.

-Justin-

I got a call from Midas today telling me they were having trouble getting the second of the two studs out. They said they were afriad they were going to break the rear exhaust manifold attempting to torch or drill it. I should have known it wasn't going to be that easy. Now they're quoting me over $500 to install a new manifold. They priced the part at $234 and want just over $300 in labor.

I know that the price of the part is above what it should be, but they could have it tomorrow for the repair. However, from what a friend was telling me the manifold is only a 2 hour job, meaning Midas wants $150/hr in labor! Is the removal/install time of 2 hours accurate?

To say the least I can only assume they're too lazy to deal with the stud removal and would rather make more money replacing the manifold.

Sad but true. I beleive it would have been ok to drive the 30 miles but it would have been loud.

Now they're quoting me over $500 to install a new manifold. They priced the part at $234 and want just over $300 in labor.

That is totally ridiculous. :screwy:

You're getting robbed on the part too. For that cost you can get a Powerlog exhaust manifold or PEM. Also, think about getting a used one. Check with Ed Morad at his EBay store.