Does anyone know if the studs on the manifold to flexi pipe join are easily removed. Went to change the standard flexi earlier this evening for a Milltek flexi that was delivered from PumaSpeed today. Whilst i was loosening the bolts all seemed to be good until i got to the last one(Typical Eh)on the manifold to flexi pipe join when the nut turned a little then sheared the stud/bolt off!, i knew this was always going to be a possibility due the stud/bolt getting hot/cold and becoming hardened and therefore brittle, what im trying to find out is has this happened to any of you guys also? and did it come out with a little heat a drift and some persuasion? are they splined or are they spot welded in as i dont want to get to heavy with the persuasion as the manifold is tubular not cast. Does anyone know if a repair kit (bolts/studs & gasket) is available for the Duratec/Fiesta ST like it is for the Zetec/Mondeo etc as ive been told i may have to buy a new manifold?,crazy for a sheared bolt/stud. Gona try Ford 2mrw to confirm this as i think a flange nut and bolt may be getting put to use if this is the case after removal of sheared item as im not buying a new standard manifold after buying the Milltek Flexi,i appreciate any response/help with this issue...

Duuno the hows and the whats but it happens to a heck of a lot of people when they change the flexi pipes. I'm sure you can just get replacement bolts. When my car had its Milltek flexi fitted by a local tuning place it sheared and they just got a new one in. Gawd knows where from but they did lol

If your stuck you can always get a cheap second hand manifold off ebay,
£15-30.

just to let you know that i have spoken to ford parts/quick co today, they told me that these studs aren't available to buy for the fiesta ST but they are for every other model and that you would have to buy a new manifold to resolve the problem! what a load of b*******, will be fixing saturday at my mates workshop where i will try abit of heat and persuasion........... car still being driven with one stud, miles til empty seems to be a bit eratic due to fuelling constantly being given duff measurements due to slight leak at join prior to lambads.

thanks to those who responded to my post!

Final update on Sheared Manifold Stud:Went to Ford Parts/Quick Co Saturday before going to my mates workshop and yes you cant buy the Ribbed press in studs for the ST or Mondeo mk3/Focus etc as fitted to the ST's factory tubular manifold and various parts of exhaust system on other models?, the system only lists/shows the manifold with the studs fitted and not available separately, crazy as there must be a bucket of em sitting in a Factory somewhere with a worker pressing em in all week.New Manifold can be got for £98 Retail +VAT?..I Thought F*** That I'll be fitting some nuts n bolts..I've eventually got the ST on the ramp and up in the air after using half the wooden ramps/runners i made moons ago to get the Cossie off the floor so the ramp arms will go under the plastic sills/skirts and get to the jacking points..Lowered cars eh,dont you jus love em. The second Manifold stud also sheared like the first one and once the other bolts are out n uve remembered to unplug the Lambda Sensor its just a matter of jiggling it over the crossmember and removing the sensor once in a vice with a 22mm spanner or special socket,the original gaskets are good to go again but remember which one came from where as they are different.
With the Flexi now gone the sheared Studs visable and the Manifold still quite warm i opted for a long Chisel/Drift and a decent Hammer to give the studs a good even hit..the first one shifts it n the second one pops it out..result..done it to the second stud n that wer the same..result again.
You have to totally undo/remove all 4 X 8mm bolts(2up,2down)from the heat shield but dont remove it just move it about to drop in the two replacement bolts,i used a couple of 13mm Sholdered flange bolts with matching flange nuts, install the Lambda Sensor before bolting Flexi into position as room is limited there..fit the gaskets,bolt up Flexi and tighten in sequence,refit heatshield fixings, pass Green Lambda sensor Plug back up to top of Engine and remember to connect it back up,Start Engine n check for leakage...OK.
I kno im lucky enough to have the use of a 2Post Ramp but if you havent Please REMEMBER to use axel stands!..
"I like our ST,I think it looks Cool but NOT enough to WEAR IT!"
After Driving the ST a little with the Milltek Flexi its so much more Responsive in all situations/gears & its money well spent i think,a mod well worth doing but remember to get them Nuts & Bolts before u get committed..
Hope you fellow STers find this of some help..

Pleased you got it sorted mate, i noticed a difference with the flexi and filter fitted, revs better and feels as if its freed up the engine.