Cat-Back Exhaust Installation Issue's

[1995eternal]

So I just got my cat-back exhaust system yesterday and just tried installing it. Actually I didnt even get to the installing part.... I got under the car to remove the old bolts that connect the stock exhaust pipes together at the flanges and I saw the stock bolts... They look like they are almost welded on there, or there is an insane amount of rust on them. All the bolts looks the same. The welding doesn't make sense, (why would someone weld the bolts on?) so that leaves me with an insane amount of rust thats collected up over the years, since its a 1995.... Does that sound about right? How do I get these bolts off, without ripping them apart? Any adive would be great ### I want to get this sucker on there, thanks.

 

[Diamondrev]

WD-40.. or take it to an exhaust shop...

 

[mannyssj13]

PB blaster works well too!

 

[MrBoxx]

By the time the bolts/nuts look welded together, they're beyond PB Blaster and WD40. Get yourself a torch, or an impact, or a sawzall. Use the torch to heat them up and then see if they'll break loose, use the impact to see if you can simply break the bolts, or sawzall the exhaust off in chunks. If nothing else, use the torch to just torch the bolts out.

 

[2GeNTSi]

Hmmm...I don't know about the NT's, but I know the 2G Turbos have the nuts tacked on, so there is no need to use two wrenches (one on the bolt head and one on the nut).

Is this the case maybe?

 

[1995eternal]

By the time the bolts/nuts look welded together, they're beyond PB Blaster and WD40. Get yourself a torch, or an impact, or a sawzall. Use the torch to heat them up and then see if they'll break loose, use the impact to see if you can simply break the bolts, or sawzall the exhaust off in chunks. If nothing else, use the torch to just torch the bolts out.

shoot, I was kinda afraid/thinkin that... I work at a Jiffy Lube so I have acess to a impact drill, plus I can use the pit in the store to get under it. Im not sure if we have a torch at the shop, that would be sweet though. Besides the impact, what else should I consider or have ready?

 

[MrBoxx]

New bolts, obviously. And new nuts. Spray bottle of water to put out fires.

Don't forget to wear your OSHA-approved safety glasses. Rust in your eye sucks.

 

[1995eternal]

Hmmm...I don't know about the NT's, but I know the 2G Turbos have the nuts tacked on, so there is no need to use two wrenches (one on the bolt head and one on the nut).

Is this the case maybe?

I dont think so... I did just get this car about a month ago, so the history of it is kinda a mystry. What I do know is that it has a 420a engine out of an Avenger in it now. So I dont think it was previously a turbo....

 

[VelocitàPaola]

I dont think so... I did just get this car about a month ago, so the history of it is kinda a mystry. What I do know is that it has a 420a engine out of an Avenger in it now. So I dont think it was previously a turbo....

The engines in turbocharged 2G DSM's and non-turbocharged 2G DSM's are completely different, so yours is not a previously turbocharged model. Nonetheless, the exhaust systems between the turbocharged and non-turbocharged 2G FWD DSM's are the same... so what 2GenTSi is describing might be what you're seeing.

 

[1995eternal]

The engines in turbocharged 2G DSM's and non-turbocharged 2G DSM's are completely different, so yours is not a previously turbocharged model. Nonetheless, the exhaust systems between the turbocharged and non-turbocharged 2G FWD DSM's are the same... so what 2GenTSi is describing might be what you're seeing.

if this bolt is tacked on there, how do I go about removing? Do I have to break it?

ok well just that about my last statement, brain fart. The bolt should just come out, but with the amount of rust/oxidation on there I think im gonna end up taking the exhaust out in sections.

 

[VelocitàPaola]

if this bolt is tacked on there, how do I go about removing? Do I have to break it?

Well, if that were the case, only the bolt would be welded to the flange. The nut would just unscrew. It's been a while since I've seen my stock exhaust system, however, so I don't remember the exact hardware that used to be down there. After reviewing CAPS and the FSM, it looks like the stock 2G (both turbo and non-turbo) exhaust systems use standard nuts and bolts, though.

The bolt should just come out, but with the amount of rust/oxidation on there I think im gonna end up taking the exhaust out in sections.

There's no shame in that... your 15 year old, rusty exhaust system doesn't exactly have a lot of resale value.

 

[2GeNTSi]

Yeah as I mentioned above, the nuts are sometimes tacked to the flange so that is probably all you are seeing - along with the accumulated rust.

Shouldn't be that bad...just grab a can of PB Blaster or Liquid Wrench and use the straw included to spray between the head of the bolt and the flange (all around to get as much in there as possible).

Let is soak for an hour or so and it should be much easier to get that bolt out. If you can't get that much leverage, than get a mallet and use it to hit the end of the ratchet or combo wrench. Just make sure to keep the wrench flush when doing so bolt to prevent stripping.

 

[Locke]

I don't even try to remove exhaust bolts anymore when they look like that. I just take them off with the torch or a cutting wheel.

 

[1995eternal]

Well holy crap, that was a freaking fun project . It took like two hours to get TWO bolts off. And thats with the car at my work, parked over the pit so we had good angles on everything, two fellow employees helpin me out and access to a shit ton of tools and crap. The two bolts that gave me the most grief were the ones that are attached to the cat or flange right there. There was sooooo much rust on these bolts the other guys thought it was welded. It took the impact drill, some special retractor bits and a couple very long breaker bars but we got it done. Other than those two bolts the rest of the project went very well. The new exhaust sounds great, not so much like a rice rocket but very aggressive. Anyways its done, thanks for the help everyone.

 

[xcelr8npimp]

I realize your project is done, but if you look at the exhaust system properly you'll see soft spots, I used an air cut off tool and invested in a compresser and cut the exhaust system up, it took a while but got it done a few hrs.