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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > NA Engine (non-turbo) / Drivetrain / Exhaust Modifications > Broken exhaust studs



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      06-09-2021, 02:16 PM   #1
toryjlarsen
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Quick question for you all, just replaced my DMF and clutch, everything is back on the car minus the exhaust, because I snapped the 4 studs trying to unbolt the exhaust pipes from the manifolds/cats... so with that being said, would it be bad for me to drive it around to a shop to get them to pop out the broken studs from the exhaust flanges?
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      06-09-2021, 03:42 PM   #2
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Of course I understand about exhaust fumes, but I just want to know if any damage would occur.
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      06-09-2021, 07:41 PM   #3
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I highly doubt anything bad would happen. Worst thing would probably be getting pulled over because of how ridiculously loud that would be to get around in
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      06-10-2021, 09:52 AM   #4
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I highly doubt anything bad would happen. Worst thing would probably be getting pulled over because of how ridiculously loud that would be to get around in
Yeah haha living in the county I'm in I'd have to be super weary of hwy patrol. Anyways I actually started drilling out the studs last night myself..... let me tell you, that is no easy task, every couple of seconds having to pull the bit out and add more cutting oil was rough, along with the pressure you have to apply. my 5/16 cobalt bit must have dulled out after the first hole though, which is crazy cause I only was able to use it once, I was able to use a 1/8 and 3/16 cobalt bits on all 4 studs from the downpipe flange and they are still sharp. Guess I gotta buy another 5/16 bit -_-
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      06-10-2021, 10:24 AM   #5
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The same thing happened to me, I drove the car to an exhaust shop and they easily took care of it.
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      06-10-2021, 11:08 AM   #6
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The same thing happened to me, I drove the car to an exhaust shop and they easily took care of it.
About how much did they charge you, if you remember?
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      06-10-2021, 01:16 PM   #7
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I dont think its gonna be an issue. Just make an appt and if the cop pulls you over, tell them they can call and confirm the appt (if they really needed to). You are literally fixing-the-ticket before you get it.
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      06-10-2021, 10:57 PM   #8
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I dont think its gonna be an issue. Just make an appt and if the cop pulls you over, tell them they can call and confirm the appt (if they really needed to). You are literally fixing-the-ticket before you get it.
Went ahead and drilled them out the past two evenings and got the exhaust back on, e90 is back on the road kickin!
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      06-11-2021, 10:41 AM   #9
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My advice for anyone with broken stainless steel studs is this:

1> Its not going to be easy.

2>Get incrementally sized COBALT drill bits.

3> Get some good cutting/machining oil (I used OATEY brand that I found at home depot, it is a pipe thread cutting oil that is nice and thick to keep your cobalt bits cool and sharp during drilling process)

4>Use a drill on LOW speed (I have a corded variable speed drill I used) low speed will not cause the bits to heat up and in turn dull.

5>Prepare to get pissed off, impatient, and sore (if your car is on jackstands and you have to be laying on the ground, trust me it get old real fast.

6>Its going to take quite a long time, so take little breaks.
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      06-19-2021, 08:29 AM   #10
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Looks like it would be easier to bring it to a shop. If I am not mistaken, they usually will map gas it and then air hammer it out. Near me is probably around 80$ and labor prices in California are higher than most places in the country
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      06-20-2021, 03:44 PM   #11
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Quote:
Originally Posted by toryjlarsen View Post
About how much did they charge you, if you remember?
$75 I think
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      06-20-2021, 03:46 PM   #12
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Quote:
Originally Posted by aphael View Post
Looks like it would be easier to bring it to a shop. If I am not mistaken, they usually will map gas it and then air hammer it out. Near me is probably around 80$ and labor prices in California are higher than most places in the country
Yeah there’s really no reason to go through all that trouble.

Just take it to a shop, ideally before starting a project.
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