replacing exhaust header gasket on '85 V6

[w261w261]

I have an '85 760GLE, 121k. It runs fine, except that I have an exhaust manifold leak, small but incrementally getting bigger. The shop where I take it is a Volvo specialist (they have a lot of them in there), but I can tell that they don't enjoy working on the V6. What they've told me is that the probability is high that a stud will break when they go to take off the manifold, and that the clearance (driver's side btw) is pretty tight, making the operation to put in a new stud potentially very labor intensive. And of course once you start, you're committed. The shop's owner, clearly trying to dissuade me from going ahead, said that it might be cheaper to pull the engine to get at the manifold. Well, the car's nice, but I don't think *that* nice. I figure that I can't be breaking new ground here, so is he right? Is it that hard to get at the studs while the motor is in? I do agree that there isn't much clearance to the fender. I'm in Fairfield, CT. The shop is Euro Automotive in Southport.

[billofdurham]

It is not that hard getting at the studs, the difficulty lies in the possibility of one or more studs shearing off. The lack of space is then critical as there is usually insufficient room to work to remove the stub. A Volvo mechanic I know carefully heats the studs, applies liberal quantities of releasing/penetrating oil and leaves them overnight to soak. He claims to have only snapped one stud, but that is one too many.

The suggestion to pull the engine seems a bit extreme but obviously he is trying to warn you in advance that this may happen if a stud snaps.

Bill.

[w261w261]

Thanks Bill.