XJ XJ6 / XJR6 ( X300 ) 1995-1997

Exhaust manifold nightmare

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Old Sep 26, 2020 | 11:37 AM
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Hugemungus's Avatar
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From: Rapid City
Default Exhaust manifold nightmare

So yesterday morning I made the mistake of trying to swap my exhaust manifold, come to find out the bottom nut for the egr that connects to the manifold stud is seized, so after stripping it I bought a chisel to knock it loose, so now not only will I need a replacement nut for the stud, I found out that the air injection tubes nut has the threads just utterly destroyed, im hoping to find a replacement egr nut at napa but have no clue where to find a nut that let's a tube pass through it for the air injection
 
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Old Sep 26, 2020 | 08:44 PM
  #2  
Darren_M's Avatar
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From: Harrison Arkansas
Default EGR Nut

Originally Posted by Hugemungus
So yesterday morning I made the mistake of trying to swap my exhaust manifold, come to find out the bottom nut for the egr that connects to the manifold stud is seized, so after stripping it I bought a chisel to knock it loose, so now not only will I need a replacement nut for the stud, I found out that the air injection tubes nut has the threads just utterly destroyed, im hoping to find a replacement egr nut at napa but have no clue where to find a nut that let's a tube pass through it for the air injection
You have several options that would require research at your end to see if any of them are a viable solution. In the past and other makes/brands I have used different repair techniques. Since I do not have a picture of your tube and nut to advise which one may be the best solution other than replacing the entire tube assembly (if available) Here are the ways I have dealt with it in the past.
#1, chase the threads in the nut on a lathe, then heat and cool the nut enough to get it to shrink down to hold onto the threads on the nipple.
#2, get a nut off of another tube, some times even one off of another make/model I.E Ford, GM etc. remove the good nut and carefully saw it down one flat and partially through the other side, spread the nut enough to get it on the tube Carefully squeeze it back together and weld. Does not need to be a deep or heave weld, just a few tacks will be more than enough. As a bit of safety to make sure when you weld it back together and have it not to tight I have inserted a round piece of aluminum or copper in the nut then clamped and tacked.
#3, Same as #2 but instead of cutting the nut, cut both tubes and splice together. TIG welding works best here.
#4, Look for a universal EGR tube that has a nut that will work and if needed perform part of #3 as needed.

There are some very nice braided heat shield sleeves available on the aftermarket that you can install over the tube when finished to help protect items around it from excessive heat and save you from burnt flesh.

Well, those are my suggestions that I have used in the past when one was NLA or way out of the budget at the time.

Good luck!
 
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