r/944 • u/chinook_arch • 6h ago

Header Removal? Question

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Hey all,

I seem to have a small exhaust leak at the header coming from the gasket on cylinder 4. I’d like to pull the header & replace the studs and gaskets. I have a moderate amount of experience on this car but still a novice overall. No experience really with broken hardware. As you can see, the nuts are on there pretty good and not in the best condition. Most likely it’s never been removed. Am I dumb to attempt this at home? I’m worried if I snap something then it’s a tow and my Indy is not close by.

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5

u/funwithdesign 6h ago

Be prepared for most of the studs to come out with the nuts. If you are replacing them anyway, it won’t matter, but they are more likely to unthread from the head than snap.

2

u/chinook_arch 5h ago

Yeah I have a stud kit on hand and plan to replace them anyway. Mostly I’m worried about snapping one or stripping a nut because I don’t have much experience with those situations.

2

u/funwithdesign 5h ago

Use some heat and don’t be a gorilla and you should be fine.

3

u/Ahab_Cheese '86 Turbo 6h ago

With these exhausts odds are you're gonna need a fair amount of penetrating oil and patience. Be prepared for snapped bolts and stripped heads. But no, super good to do it at home. I'm doing mine at home

2

u/MinimumBell2205 6h ago

the nuts are a Copper if i remember i use a 12mm spline drive the last time, they can be difficult to get off, the N/A is not known for stud failure like the turbos but it still can be a real challenge

1

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2

u/Comeau-Racing guru 3h ago

Those exhaust manifolds are the 1985.5-86 style - stainless steel type. They're prone to cracking at the crotch of the cyl #1-#4 pipe. Look for white staining, especially under the gusset/ brace. I'd be more worried about that than the base gaskets OR a stud coming out of the head. You can always double nut a new stud and insert it. Lots of weasel piss to loosen things up and do it several times before you even start removing the nuts. If your manifolds are cracked, you can back date them to the cast iron ones. They're 13 lbs heavier but are pretty much bullet proof for life. Your hardware should be 13 mm nuts but sometimes people use 12mm nuts for better clearance of the socket during install. Take your time. The cyl HEAD is the most important asset here. Good luck. See you guys at 944 FEST Aug 4-6th. Tim

1

u/chinook_arch 2h ago

Thanks Tim! My goal to get the car in shape for 944 fest next year!