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Old 04-16-2011, 08:12 PM
JohnS JohnS is offline
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Join Date: Sep 2004
Posts: 145
You can replace the flex joint without removing the entire manifold, but you may find it is just as easy to do remove the whole thing.

Tools you'll need
- a method of cutting off th old flex joint - cutoff wheel or the like
-stud extractor tool - this fits on the stud directly and will allow you to remove it and install it without damaging the threads. You want the type that looks like a socket and has jaws that clamp on the stud when you turn it, that's the only type that will fit. NAPA carries them about $15
-assorted socket extensions and u-joints

Here's what you have to do:
-remove coolant tank, aluminum heat shield, air intake above turbo, etc, etc, so you have enough room to work, you do not have to remove the turbo, but you do have to get the waste gate linkage out of the way
-cut the old joint completely thru, rotate it as needed to get access to the entire circumference
-remove the nuts from the four studs, some of the studs will come out with the nuts, that's OK; you want to be real careful here, if any nuts are tight, go easy, use penetrating oil, do not bugger up the hexes, use heat if necessary.
-remove the rest of the studs with your extractor
- pull off the manifold section,
- clean everything up, inspect your manifold gasket, if it looks ratty buy an new one and cut off the section you need for the two ports
- install your new flex piece, leave the clamps loose, make sure you can access the clamp screws once everything is in place
- Don't put the studs in yet, take your manifold section and put it in place up against the flex piece.
- use your stud extractor to insert your studs
-install and torque your nuts
-tighten up the flex joint clamps
-put all the other stuff back
-have a beer

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