Broken exhaust studs

[rics87]

I have an 87 MJ 4.0 amnual trans 2WD. It's been having an exhaust leak, but lately the leak is getting worse. Anyways, finally got around to buying the gasket. Did the R&R and when I was tightening the nut onto the stud at the back of the engine, THE BUGGER BROKE! I says great now what. Has anyone gone through this? I'm thinking either pull the head off as there looks to be a clearence issue with the firewall and my drill. Or taking off the cross member and motor mounts and with two floor jacks move the engine/trans together just until I get the space needed to repair the broken stud.

[XJGPER]

Can you get into the area with a right angle adapter and a left handed drill bit? I took out a broken stud out of a head i did last weekend i had on a bench during a headjob on a ZJ, i was able to use a pointy chisel and manually turn it to undo it. (it wasn't rusted in though came right out after about 30 taps)

[kastein]

How much sticks out of the block?

 

If you got lucky and it broke like a quarter inch up from the block, try threading another nut onto it, weld it down, and turn it out. The weld heat may even break the rust loose and make it come out easier.

[mnkyboy]

I went through this on my XJ,Unless you can get ahold of it save some trouble and just pull the head.

 

a head gasket on a 4.0L is pretty easy.

[dasbulliwagen]

The stud breakage is very common, the very front stud does the same thing, so you may want to replace that one at the same time. The same thing happens on the 2.5 also. Chrysler has a TSB on these for an updated part number, torques spec, and nylon spacer and nut. You need to pull the intake and exhaust off anyways, will only be a little more to pull the head.... good time for a bunch of new gaskets too. Good luck.