Broken Cylinder Head Stud 4.2 engine

[rcmcewen]

Having a quiet drive on Sunday when a low thud and minutes later clouds of steam.
Couldn't find a burst hose and then I noticed a small dent in the middle of the bonnet.
Further inspection found that the third cyliner head stud from the rear on the induction side had broken where it screws into the bottom of the block and had been launched vertically presumably by the water pressure.
How on earth does one remove the broken part of the stud from the internals. Has anyone had any experience of engineering companies who can do the work, preferably near Wiltshire.
Any help will be appreaciated.

[e600]

I feel your pain. There is a bit more to come! I know that VSE can tackle such a job, however, its either engine out strip and send to them, if you are the practical sort or send the car to them. You might get a few replies telling you how someone done the repair on the side of the road late on a Saturday night with nothing more than tweezers and his girlfriends tights, but the reality is its a real PITA and almost impossible without access to a good machine shop and a skilled individual.

Best of luck, and let me know how you get on

Regards
Pat

[J44EAG]

Hope I`m not teaching Granny to suck eggs and am probably barking up the wrong gum tree without a paddle here. Just an idea which may or may not be relevant.

I`m not in any way that knowledgeable about XK engines but when I first read the post I envisaged a broken stud lodged on the top face of the block. My immediate reaction was..... "Ah, a job for an easyout tool, albeit with the head removed".

Then I re read the post and saw "bottom". At that point I thought, long stud with remains buried within the block structure. That is more of a problem!

Broken studs in the top of the block are not usually too much of a problem and i`ve previously used similar tools as in this link to good effect.

http://www.amazon.co.uk/Silverline-3717 ... 512&sr=1-3

A more high tech and sophisticated version is in this link.

http://www.google.co.uk/aclk?sa=l&ai=CA ... ut&cad=rja

These tools may not be suitable but I thought I`d just pop this into the discussion even if perhaps not quite what is needed.

I can recommend Geoff and Dave, two brothers, at Bristol Autocare on the Redfield/Hanham borders in Bristol. I don`t know if they are still operating as it was in 1991 that I last used their services. Both ex Rolls Royce employees, then running a superb engine reconditioning workshop just east of the A431 and A420. Top guys but both probably in retirement now. Worth investigation as this sort or difficult job would be right up their street.

Hope that helps.

Mike K

[Geordie]

Not sure of your precise location rcmcewen, but I am aware Arun Motors near Haslemere / Pulborough, West Sussex have undertaken stud removal before. Not an easy job, lots of man hours

[rcmcewen]

UPDATE UPDATE
Engine out, head off, and well I never, two more studs broken and repaired using helicoils in the block. Spoke to Classic Car Engines (advertise in JEC) and ultimately got them to do a complete repair as well as a few other things like crankshaft oil seals. They think the issue is because US owners don't use antifreeze and the studs simply corrode away, they use stainless studs.

Engine showing new studs fitted, core plugs removed.

CCE have a very smart workshop, mainly 6 cyl XKs, and have frames on which they will collect the engine. Gave me a quote and met the price including a few extras.
Done about 500 miles so far.

[oz5986]

hi, i feel your pain. had same problem myself with a series 2 4.2 engine. Unfortunately i have to agree with previous reply. You are going to have to strip it down. The last thing you need is to try and cut down the stripping down job because of the danger of small bits of metal getting into things they shouldnt.
My dad has rebuilt about 16 E Types over the years and if there was a way im sure he would have known it. The problem is, and i find it hard to work out jaguars logic in this. A 3.8 engine and early 4.2 has all short head studs that thread into the top of the block. Then someone had the idea of putting the studs right down in the bottom waterways. lol..
Now if thats not a recipe for disaster i dont know what is... They did it to improve cooling but its a move thats bound to create expensive & time consuming problems. You need to get it drilled out and and an alu coil put in. Obviously have the others checked while its there or you could be doing this whole job again in the near future. Fortunately they arent all long studs and the short head studs dont have this problem. Hope this gives you a little help. Regards Oz

[sean]

On a slightly different note once the repair is done you may want to consider the small dent. I managed to drop a polisher on my e type and put a small dent in the wing.
Had one of the dent people fix it it was a bit like going to the dentist as he tapped and levered the wing, but. hey-presto when he was done I could not even see where he had worked amazing.

Hope you get sorted

[bobhayne]

Hi there!
I have a 4.2 Ser 2 E Type and it has a couple of broken studs, just wondered if it would be ok to replace the broken long ones with short studs fastened in to the top of the block with some sort of helicoil. Any one done this before? Any thoughts?

Thanks
Bob

[rcmcewen]

Hi Bob,
Presumably Jaguar fitted the long studs on the 4.2 as they were unhappy about fitting studs into the top of the block so close to the bores. 3 of mine had been done as you propose in about 2002 and were still OK in 2012 but I made the decision to go back to long studs when I had the recent failure.
Classic Car Engines near Upton on Severn (ad in JEC mag) make and install special stainless long studs including drilling and tapping block as necessary, but it does require a complete engine strip down. They did a very good job for me at what I considered to be a reasonable price.
See message and photo above.
Regards
Roger

[bobhayne]

Thanks Roger for your most helpful reply. Can you share where you obtained the short studs and inserts and where you had that work done? Much appreciated!

Regards

Bob

[rcmcewen]

Hi Bob,
The short studs and inserts were done by a previous owner so I cannot help you on this.
Regards
Roger