After installing headers on my TL several months ago, I noticed what sounded like an exhaust leak. After some closer inspection, several of the studs that hold the headers on have simply snapped off... anyone here had the same problem? If so, what did you do to fix the issue? I plan to simply replace the studs, but my guess is something is causing this and the new ones will also break.

 

are you saying that the "screws" that come out from the engine block broke in half? is it in the front or rear of the engine?

 

Yeah, exactly, and both front and back...

 

Sounds like they were stretched when taken off then when put on possibly put on too tight, causing them to strech a little more making them really weak.

as for fixing it, id replace all of them then retorque them to where they are supposed to be

 

lets say the "screw" is to short to use the double bolt method to remove it, how else would you be able to take it out?

 

Just some good ol' vice grips will do the job if you don't care about the threads, which I don't since they are broken anyhow.

 

Yup!

 

Was a torque wrench used on the initial install? If not, make sure you use one this time around.

As you found out, those studs can strip, and break off all too easy. The most likely cause was overtorquing during the install. Use a torque wrench at the proper settings, and you'll be fine.

 

The weird thing is, they broke off MONTHS (8 mos actually) after they were installed, and yes a torque wrench was used during the install.