The TD5 - (as fitted to the Land Rover Defender and Discovery 2) is superb engine but sadly suffers from warping exhaust manifold and broken studs. The root cause of this is due to the different expansion and contraction rates of the aluminium cylinder head and the steel manifold. Eventually the studs break, the manifold warps and the gasket leaks (often causing a high pitched 'squeal' under heavy acceleration).
To combat this the clever guys and girls at Gigglepin have developed a replacement stud kit that uses longer studs and spacers that allows for more expansion and contraction, stopping your exhaust studs from breaking prematurely. Available as a Stud Kit or as a complete Stud & Gasket Kit which is supplied with Exhaust Manifold Gasket, Turbo to Manifold Gasket, Coolant Housing Gasket and 2 x Copper Washer for turbo oil feed pipe.
Before fitting we recommend that the mating face of the manifold that meets the head is lightly skimmed to ensure that it is 100% flat and clean. Also it is advantageous to cut a slot into the webs between the ports on the manifold, again to allow extra movement due to expansion and contraction.
The nuts should be tightened to 25nm (18lbf.ft).
This kit consists of 10 x Extended Exhaust Manifold Studs, 10 x Spacers and 10 x Flange Nuts.