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Tdi4

Member Since: 24 Oct 2014
Location: Houten
Posts: 513

2008 Defender 110 Puma 2.4 CSW Stornoway Grey

Studs exhaust manifold to turbo keep coming loose

In the next couple of weeks am going to a workshop to do some maintenance. And I want to tackle this problem once and for all.

The problem is that the studs are coming loose mainly in the summer and on load (caravan, 4 kids, mountains etc). Not the bolts but the studs.

What have I done so far.
1. Fitted the thick spacer (bought it at alive)
2. Got bigger studs m10

All with no succes.

Any ideas?

I run an alive remap, with a bespoke turbo, allisport radiator, allisport intercooler, decat, 100 mm air intake a defender from 1984 pretending to be a puma with a touch of Range Rover

20th Mar 2018 8:31am

Low-Range

Member Since: 30 Sep 2016
Location: BC
Posts: 41

loose studs

You can buy a compound that you put on the threads before you tighten them. http://www.all-spec.com/UserFiles/Images/P..._WebXL.jpg

20th Mar 2018 8:38pm

Tdi4

Member Since: 24 Oct 2014
Location: Houten
Posts: 513

Thnx!

But is it sufficient temperature resistant? As far as I can see ir’s Rated > 300 degrees. But the exhaust manifold will reach > 800 degrees? a defender from 1984 pretending to be a puma with a touch of Range Rover

20th Mar 2018 8:50pm

Low-Range

Member Since: 30 Sep 2016
Location: BC
Posts: 41

studs

Different products have different ranges.. https://pilotshq.com/loctite-superflex-red...11054.html

20th Mar 2018 8:56pm

Tdi4

Member Since: 24 Oct 2014
Location: Houten
Posts: 513

Correct but this product is rated to 315 degrees. I haven’t found a product which can withstand the temperatures of a exhaust manifold. a defender from 1984 pretending to be a puma with a touch of Range Rover

20th Mar 2018 9:29pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17363

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

I suspect the problem is caused by the studs expanding more/faster than the flange through which they pass, thus reducing the tightness of the nuts, in turn allowing the nuts to loosen more. I have always had a similar problem with the studs securing the front branch of the manifold to tne head, now exacerbated by the failure of the thread in one hole in the head (I will be fitting a Timesert to this when I get time, but inevitably it is the hole behind the alternator bracket so a lot of dismantling is required to get at it).

You may find that fitting longer studs with a spacer of a different material with a greater coefficient of linear expansion, such as a hard brass, between the nuts and the flange does the trick. The idea (fairly obviously) is that by expanding a little faster than the stud the spacer maintains the tension needed to prevent the nut loosening.

20th Mar 2018 10:48pm

Tdi4

Member Since: 24 Oct 2014
Location: Houten
Posts: 513

Thnx Blackwolf,

Sorry but I can’t figure out where to put the spacer. Stud goes into manifold and then??? a defender from 1984 pretending to be a puma with a touch of Range Rover

21st Mar 2018 5:54am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17363

Longer stud into manifold, turbo onto studs, spacer onto stud, nut onto spacer.

A very similar thing is often done on where TD5 exhaust manifolds bolt to the head to prevent the studs from breaking for similar reasons.

21st Mar 2018 8:37am

Tdi4

Member Since: 24 Oct 2014
Location: Houten
Posts: 513

Okay will try that (as well

).

But I'am trying to understand this solution, if it works I don't need to understand it. But what is different? The bolt is put on tight but still the stud comes loose. What is the function then of the washer? a defender from 1984 pretending to be a puma with a touch of Range Rover

21st Mar 2018 9:18am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4785

I have blocks on my Td5, it's worked for the last 5 years

Click image to enlarge 2002 90 Td5 Station Wagon
1990 Vogue SE
Triumph Tiger Explorer 1200
Td5 90 Thread http://www.defender2.net/forum/topic50767.html
Tdi 110 Thread https://www.defender2.net/forum/topic69562.html
RRC Thread http://www.defender2.net/forum/topic54492.html
Instagram http://www.instagram.com/george_grafton

21st Mar 2018 9:35am

Tdi4

Member Since: 24 Oct 2014
Location: Houten
Posts: 513

Hi Grafty,

Are those stretch bolts? a defender from 1984 pretending to be a puma with a touch of Range Rover

21st Mar 2018 9:44am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4785

No just standard 8.8

2002 90 Td5 Station Wagon
1990 Vogue SE
Triumph Tiger Explorer 1200
Td5 90 Thread http://www.defender2.net/forum/topic50767.html
Tdi 110 Thread https://www.defender2.net/forum/topic69562.html
RRC Thread http://www.defender2.net/forum/topic54492.html
Instagram http://www.instagram.com/george_grafton

21st Mar 2018 12:25pm

Tdi4

Member Since: 24 Oct 2014
Location: Houten
Posts: 513

Hi grafty

Then I didn’t understand you correctly. Another Dutch guy trying to speak English

What are blocks? I ‘ve looked at the picture and I didn’t see anything else than the bolts? a defender from 1984 pretending to be a puma with a touch of Range Rover

21st Mar 2018 4:04pm

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4785

There are cylindrical metal blocks which the bolts pass through before the manifold face

I'll edit the picture to explain better

21st Mar 2018 9:06pm

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4785

The section in red is the block which expands to keep tension on the bolts

21st Mar 2018 9:47pm

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