Rusty Bolts

[itreflop117]

Alright, I just received my catback in the mail. I don't want to pay some muffler shop to screw me of my money. So I decided to do the job myself.

The problem is... I have legit rusty ass bolts. Like there is a layer of straight up RUST over the WHOLE screw... For example, the rust is so bad, i can't even put a socket wrench on the screw because I can't even tell where it is...

Sooooo, my questions for you guys are:

1. What can I possibly do to remove the rust?

2. What mm size are the screws/bolts? So I can find the right socket to use.

3. And finally, how would I go about taking out the O2 sensor and putting it back into my new exhaust?

Once again, thank you for your time guys! All the info is greatly appreciated!

[Yuko]

Ah, go old Chicago rust. Seven years and I never missed that since I moved south.

Okay, if the cat-back is a direct bolt on, it's easy. There's two ways to approach that. You can soak the bolts/nuts with PB blaster and work the nuts loose with good vice-grips and install with new hardware. Or you can saw off the old bolt/nut, punch out any reminding studs, and bolt the cat-back with new hardware. The bolts and nuts are around 15-17mm, not sure. As for the O2 sensor; many auto part stores loan out a special socket to remove it with a ratchet but an usually be removed with a wrench. Might as well get new rubber hangers for it too.

[tacosteelersman]

I run the car till at operating temp then spray the 02 sensor threads and wirebrush them repeat,repeat,repeat . Cut the cat bolts, I like a grinder with a cutting wheel, WARNING try to not use a sawzall on the cat due to the vibration nocking the cat appart internally. Install new hardware

[speedy25]

If you dont have a "flame wrench" (oxy/acetylene torch) 2nd best would be a grinder and lop off the bolt or nut end. You will still have to either twist out or bash out the remaining piece. While sometimes you can use penetrants to take these apart typically exhausts WONT respond to that method.

Dont forget gaskets and new bolts. You also may have to do a little grinding to get a smooth flat flange to bolt to.

-SP

[blb]

If you don't have a already have an oxy-acetylene torch, the easiest way is to go to Harbor Freight and spend $10 to $15 on a 4 or 4 1/2" angle grinder and cut off the head of the bolt or the nut, whichever is easiest to access. Obviously wear eye protection...you'll be done in 5 minutes.

[gold94corolla]

So your bolts look like mine ehh?



I tried soaking them and everything except for torching them off. If all else fails, there's always the good old saw



Worked like a charm after a minute of cutting



of course I had to replace the entire exhaust.....

[Bitter]

1. don't bother trying to take them off, penetrating oil, etc.
2. get an angle grinder with a course metal disc or cutting disc
3. grind one end off
4. knock whats left out with a hammer or punch
5. do the same to the other side

srsly, its that easy. just get some new bolts/nuts of the proper size, use stainless if you think you'll be changing it or taking it off.