Removal of Exhaust Bolts

Hi All,

Trying to switch out my exhaust assembly rear of the cat, and the bolts are just blobs of rust. So far ive tried hammering a socket onto them, vise grips and torch/PB blaster. I guess at this point i've got a few options:

1. Dremel a notch into the bolt (red arrow), and use a flathead socket on a breaker bar
2. Weld a nut onto the end (dont have access to a welder but I would buy a cheap one from HF)
3. Cut them out.

My question is, where would I start with the cut? I've got a dremel, grinder and recip saw. I'm thinking cut the head off the bolt, then either extract the screw or punch it through somehow. Suggestions? Thanks!

 

Yes, i'll probably break out the dremel tomorrow, but where would you start?

 

Sawzall with a carbide metal cutting blade. Cut the nut off. That appears to be the easiest to access from the side. I've messed with all kinds of "normal" blades when cutting metal on a vehicle and finally picked up a carbide blade. Those bastards cut through metal like butter. You'll never use a demo blade or any other after you try it. That nut would be off in a couple seconds.

 

Sounds good, then extract with lefthand bit?

 

If you cut the nut off you should be able to get the exhaust pieces apart and assess the situation. If the bolt is welded to the flange (I can't remember if it is loose or welded in place) you may have to cut it off flush on both sides of the flange and then drill a new hole to run a bolt through. I don't know exactly what you're trying to do, but if you get the two apart you can figure it out from there

 

when I did my o2 sensor I cut a side notch in the nuts then chiseled them open with a flathead screwdriver. But in your case, just cut the bolts off and put fresh new ones

Don't forget to put antiseize on the new bolts. It will make it easier next time!

 

I would also cut the nut off the back and replace the hardware, definitely use antiseize when you put it back together.

 

Pony up for some stainless hardware.

 

After work today i'll post an update, and I've got new bolts, donut gasket and flange.

 

I myself like using a Cut of wheel in my 4 1/2" grinder .

Just more comfortable for me smaller package

I have not used my Sawzall since it got taken off my welding Truck around 2001

 

After work today i'm going to start with a dremel and cutting disc....if that doesnt work, then i'll move to either grinder or sawzall.

Edit: Didn't get to start today...bought a cheap welder instead.

 

No luck...extractor won’t get a good bite on my drill chuck, it just spins. I tried a crescent wrench, no dice. Maybe a bigger wrench? Any suggestions?

 

I wouldn't use that extractor; if it snaps off you will have a piece of hardened steel in there to deal with. Are you trying to get a new bolt to go in there? What is your plan for putting that pipe back in to the system?

It looks like if you finish grinding the head off that bolt you can remove the pipe and you will have a piece to maybe grab onto. You might end up drilling the whole thing out, and afterwards you can maybe bolt it back together.

 

You could just grind it flat with an angle grinder. It might take a while using a Dremel tho.

 

That's what I would probably do. Grind it flat with a grinder disc or use a carbide burr bit.

 

It looks like once you take care of that bolt head you can just remove the coupling and get some new fasteners, gaskets etc. and be on your way.

 

Thanks, yeah I’ll probably do that. The dremel was taking forever so I used the grinder. I’ll continue tomorrow when I get back under the truck. Appreciate all the advice guys.

Also, yeah I’m getting all new hardware. I have a whole new exhaust assembly from just past the cat to the tailpipe.

 

I had this job forced upon me during a camping trip with my brother last Fall.

Lost an afternoon replacing the old and busted one with a replacement in the parking lot of an auto-parts store. God bless my brother who was an absolute champ and helped me get us back on the road quicker than if it was just me!

Do yourselves all a favour and check-in on this area every now and then!