[fravel]

So, I'm halfway through swapping out my factory exhaust for the AFE mid-pipe + BMW PE combo and I've hit a small snag.

While I was unbolting the midpipes from the headers, one of the studs sheared off. The diagram below should make clear what I am describing; Item #5.



Now, in atticipation of this problem I ordered replacements before I started based on the part numbers I got through that diagram (07119906928). These are standard hex head bolts (according to ECS) - however the studs that are on my car do not have hex heads, what I have are just thin circular heads with no means of fixing a tool on them to be turned, similar to what is actually depicted on the diagram.

I was hoping it would just tap out but I've had no such luck. Now I'm turning to the forum hoping someone can offer some insight as to how these studs are actually affixed and some best practices for removing it.

Thanks!

[torkles]

Drill it out.

[Inline]

Mine were welded on 330i so I would just drill them out.

[StealYourFace]

Got a torch?

[NA55]

Try an air hammer to chisel the weld off and then push the stud out..

[avocet]

Heat the crap out of the flange then try to punch the bolt out with an air hammer or a big fucking hammer and punch.

[fravel]

After some googling it appears that this is a common problem on the E36's. Some people reporting flange separation after using the heat + air hammer method, so I've purchased a metal cut off wheel for my dremel and some cobalt drill bits and will be attempting to cut it off/drill it out tonight. Not excited about that prospect, but whatever.

Thanks guys.

[TheSt|G]

Very common issue with older BMWs. AFAIK the factory studs are splined at the head, and use that for a friction fit on the header side. The nut on the midpipe side then tightens it down to provide a clamping fit.

Take your time and drill them at a very low speed with lots of oil, the bolts are pretty hard steel. Expect to have to dremel off the heads.

[fravel]

Originally Posted by TheSt|G

Very common issue with older BMWs. AFAIK the factory studs are splined at the head, and use that for a friction fit on the header side. The nut on the midpipe side then tightens it down to provide a clamping fit.

Take your time and drill them at a very low speed with lots of oil, the bolts are pretty hard steel. Expect to have to dremel off the heads.

Victory!

I used my dremel to cut the bolt off flush with the flange, then drilled it out using various sized drill bits. Once I had the majority of the shaft of the bolt removed I wedged the dremel under the bolt head to make a slot. Got enough space, slide a screwdriver under the lip and popped it out.

It sounds so good.

[TheSt|G]

Originally Posted by fravel

Victory!

I used my dremel to cut the bolt off flush with the flange, then drilled it out using various sized drill bits. Once I had the majority of the shaft of the bolt removed I wedged the dremel under the bolt head to make a slot. Got enough space, slide a screwdriver under the lip and popped it out.

It sounds so good.

Lucky the car isn't that old. I had to do this recently on a 15 year old 3 series that lived in New Hampshire(salt central). They had just fused to become one.