1996 GTI Breaking Exhaust Bolts

[etemplet]

This is the 3rd time this ski has broken the exhaust bolts on top of the manifold. Then engine seems to be in pretty good shape and runs great. I believe there is some misalignment causing stress and the normal vibration of the engine is the catalyst. I do have the exhaust bracket bolt in place. I bought a new bushing because I was told if that bushing is bad the bolts will break. So today..... I'm pulling the exhaust and will check for stress and I will eliminate that stress but... any input would be welcome. This is so weird. I got another ski with the same engine and no issues at all.

Failure goes like this....First thing to break off is the Threaded Stud, next is the bolt to the left of it. That does tell me something of the misalignment. I might just replace the tuned pipe assembly... so the book calls it. LOL Here I go !!

Touchdowns everyone and stay safe !! Happy Easter !!

 

[mikidymac]

The only thing that i have ever seen cause the bolts/stud to break is worn bushings and sleeves.
For alignment, if you do everything finger tight before torquing them there is really no way it can be an alignment issue. It has to be from the pipe moving/vibrating on the supports putting stress on the manifold joint. Make sure you are using the correct bushings, sleeves and big fender washers.

 

[etemplet]

That is what I found Miki so "SPOT ON" !!
To clear things up. I only addressed this issue once previously and it was last year. I did talk to Tom at SES about it and he told me if the bushing was bad it would keep breaking the bolts. So based on that I ordered two sets of bushings and had them on hand. As you may have noticed I was going to find out the cause "today" and I have another pipe and was prepared to "go the distance". LOL

As result of this finding, I am going to simply replace the bushings with new and do it up right as always. I would suggest that anyone that removes this pipe for any reason have a look at the mount bushing. It can cause a lot of grief I'm sure. Fortunately I got a look at it before more damage could have been done.

Pictures are of the New bushings. You'll need the spacer as well. Good Luck All and Happy Easter !!

 

[etemplet]

On amazing thing that happened as a result of this process. I had an exhaust gasket in a kit for a 687X I'm restoring. I could have easily taken the gasket from the kit but I didn't. I looked in my gasket drawer and didn't see one but I had one more place to check as I stockpile parts sometimes. I had a stack of gaskets and such in a box where I keep new parts. I figured I might have one in there. So... I grabbed a handful of new packaged gaskets... normally I would have just looked for the one I needed and taken that one. So.....

The amazing part is.... when I pulled all the gaskets I noticed something in the bottom of the storage bin. Now this bin is full of parts that are packaged and arranged it is isn't really a mess. I can find what I need. Anyway.... the rest of the story....

I've been missing my Rosary my Mom bought me for about 3 months. It was pretty expensive, 18K gold and very pretty. My Mom passed away in 2014. She used to always say, "It's not lost it is just misplaced." I've prayed about this a lot and I've looked everywhere I could think of 4 times. I surely found out where it wasn't. YES... there was my rosary bag.... I opened it and was happy to see all was well. Unbelievable !!! Don't ask me how it got in there but.... Thank You God and St. Anthony and Mom and everyone for their prayers. It isn't about finding the Rosary but an affirmation I've been asking for. I think I got both. God Bless Everyone and Happy Easter !! We are in the best of hands, all this craziness will subside soon and life will be better than we could ever have hoped !!