Hello,

1985 XJ6 Series three. I'm replacing the lower wishbone bushings which required removing the catalyst to remove the pivot bolt. One of the rear manifold studs twisted off during this process. Was reading a thread from this spring where it was mentioned to just swap the holes rather than drilling out the broken stud. I had noticed there were two spare holes, but are there any issues with just swapping the position of the studs? Do I have to do both manifolds to avoid interference and ensure access or can I just swap locations on the rear manifold? It looks like the remaining stud will interfere with the clamp so I'll have to remove it (or break it off) as well, correct? Maybe these are obvious questions but I'm trying not to make a bad situation worse.

Thanks for you help! Ben

 

however you do it, do it outside.

remove the manifold in question, not easy, not hard, only a p.i.t.a. to get to the bottom nuts. One by one is what does it.

if you are changing position of studs, you need to do both studs. One opposite the other, Lots of penetrant fluid at the studs.

and chances are, the other stud might break when loosening the nut.
Better to have new studs handy.

 

Jose,

Thanks for the response.

I've got the catalyst out and only broke the rear most stud. I'm trying not to remove the manifold as I only need to reinstall the catalyst after replacing the lower suspension bushings. If I were going to drill out and retap the manifold I agree I would have to remove it as there's no clearance to do that on the car. But, it sounds like I can use the currently unused holes and just rotate the clamp 90 degrees. The first one broke high on the stud where the threads end, but then I broke it off flush at that flange with a stud remover. I'm hoping after soaking in penetrating fluid the second will come will come out with the stud remover, but if it breaks off flush then I'll be ready to reinstall it rotated with new studs.

I have ordered four new studs and nuts as well as manifold to catalyst downpipe gaskets. It seems the "olive" seal at the catalyst outlet is unavailable at Welsh and Moss. Does anyone know if there's an alternative that works? It doesn't look like a very unique part. I may try my exhaust guy or just put some sealing paste on it and reuse the old one.

Now to replace the suspension parts and hope the catalyst parts show up quickly.

Thanks again, Ben

 

Ben,
you are very welcome.

if you are in the USA, SNG BARRAT USA store should have the onion seals.

Otherwise, they have the UK and France stores.

 

Google "EBC9388 Jaguar". You should get plenty of hits. But, yes, I reckon you could use a generic one as well

Cheers
DD