Removing damaged or seized aircraft exhaust studs can be one of the more difficult maintenance tasks on piston aircraft engines. The Cadmium plating on the exhaust studs melt at 610 degrees F. while exhaust gases and exhaust stacks typically run at 1400 degrees F or higher. The loss of cadmium’s sacrificial corrosion protection and high temperatures allows rust to eat away at the stud structure leaving a weakened stud that is corroded into the cylinder head. Rust erosion leaves a smaller diameter stud that can twist off easier than when the stud was installed. It is prudent to replace the studs before the rust corrosion weakens the studs to the extent that they are not strong enough to turn the threads out of the cylinder head.
TOOL134 Aircraft Exhaust Stud Extractor Set
The McFarlane TOOL134 Stud Extractor Set is designed to securely remove seized, corroded, or damaged exhaust studs without slipping. Removal torque is applied on center of the stud to prevent twisting off the stud. This aircraft stud removal tool creates a strong collet grip by tightening internal components around the stud threads, allowing mechanics to remove exhaust studs without slipping on the threads. Torque can be applied precisely on-center of the stud. There are similar thread gripping tools on the market, but none that hold tight enough to not slip on the threads and be small enough to clear the cylinder cooling fins. What makes our tool unique is that it is both small enough to clear the cooling fins and grips tight like a large dimeter stud remover. Other stud removing techniques are time consuming and are at risk of failure. The Tool 134 has shown that it can grip tight enough to even remove stuck studs where the threads are missing or the stud has been twisted off. Once the stud is removed, the tool releases the stud with simple wrench action. You do not have to grip the stud in a vise or hammer the stud out of the tool. Tool 134 is available in common aircraft exhaust stud thread sizes including 1/4-28, 5/16-24, and 5/16-18.
TOOL135 Aircraft Exhaust Stud Driver Set
After removing damaged hardware, the McFarlane TOOL135 Stud Driver Set helps aviation mechanics quickly install replacement aircraft exhaust studs. The stud driver threads directly onto the new stud and is torque wrench friendly.
Once the stud is seated, the driver releases easily by loosening the locking components and backing the tool off the stud. TOOL135 is available in the common aircraft stud thread sizes .
Designed for Lycoming and Continental Engine Maintenance
TOOL134 and TOOL135 are ideal for aircraft exhaust system maintenance on many Lycoming and Continental engines commonly used in general aviation aircraft. These aviation mechanic tools help reduce installation time, improve stud alignment, and minimize the potential for broken studs that must be drilled out of the cylinder head.
McFarlane Aviation recommends pairing these tools with FAA-PMA approved stainless steel exhaust studs and Black-Max™ coated Stainless Steel exhaust nuts for improved corrosion resistance and long-term durability in high-temperature exhaust applications. Regular lubrication of the Tool 134’s collet and threads with DAM Exhaust Lubricant can also improve grip strength and extend tool life.
Improve Aircraft Exhaust Maintenance Efficiency
For aviation mechanics performing cylinder, exhaust, or engine maintenance, McFarlane’s TOOL134 Stud Extractor Set and TOOL135 Stud Driver Set provide a faster, cleaner, and more reliable method for aircraft exhaust stud replacement. These specialized aircraft maintenance tools help mechanics spend less time fighting seized hardware and more time completing professional-quality repairs efficiently and correctly the first time.