ProMaxx recommends the extractor only be inserted for about 1/4” for two reasons. The technician can now tap the ProTractor screw extractor in and back the damaged stud out. The exhaust manifold repair kit from ProMaxx includes the ProCutter, a cool little device that, when positioned in an air or electric drill after boring a hold dead-center, can deburr and flatten the stud, remove the corrosion in the tapped hole, and make it look like new - ready for extraction in just under five seconds. This usually results in a broken extractor when attempts to dislodge the remnant stud fail. This lock washer effect, or burr as it is most commonly referred to, increases the complexity of removing the damaged remnant. This stretching, or tensioning of the stud, breaks the core of the stud first, and then unwinds the threaded portion, turning the thread into a lock washer boring into the soft aluminum core, lodging the stud fast. When the manifold tensions the stud, the material eventually becomes “plastic,” in engineering terms, and does not return to its original length, but becomes deformed by stretching beyond limits and fails, usually breaking just below the surface of the cylinder head. It’s just a matter of when they will fail, not if,” says Marvin Stach, regional sales manager for ProMaxx. Cold or hot climates really don’t make much difference where these parts fail it happens everywhere. “Most technicians believe the rust belt states have a monopoly on these repairs. These extreme temperature variations twist and warp the exhaust manifolds, resulting in sheer and tension forces on the retaining bolts or studs. Add extreme conditions, such as towing heavy equipment or carrying large payloads, and cylinder head temperatures can rapidly climb to over 1,200 degrees. starting and stopping the engine, cylinder head temperatures can range from zero to 1,000 degrees under normal conditions when driving in cold or hot climates. “The other half is breaking the grip of the damaged stud lodged in the head.”ĭuring duty cycles, e.g. “Engineering the system to machine accurately solves only part of the challenge,” says Jeff Del Rossa, president of ProMaxx. This results in dead-center alignment of the stud and quick machining – usually 40-50 seconds. The tooling is precision-made to eliminate bit wobble and includes a micro-edge that seats the bit within five seconds. Special triple-fluted machine-turned tooling bits that exceed aerospace specifications can cut through the hardest of damaged bolts found in gas and even hard-working diesel engines. A precision CNC- machined aluminum ProPlate is fitted with a made-for-life hardened steel bushing, along with machine-turned stainless steel fasteners that ensure perfect alignment over the damaged stud when mounted to the cylinder head while in the vehicle.
The device features several innovative pieces that ensure success when making the repair. This is a risky repair since each one encountered is unique and, frankly, unpredictable in terms of the process and cost to remove them - until now. The kit ensures precise alignment by machining dead-center and perfectly perpendicular to the surface of the head while in the vehicle without removing the cylinder head. The solution is a complete system that targets three major challenges when removing broken exhaust manifold bolts: accessing the damaged stud, centering the hole, and drilling straight. ProMaxx repair kits are engineered to improve ease and repair times when removing and repairing the exhaust manifolds in Dodge, Ford, GM, and Jeep engines.
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