Well fudge...
I had an earlier thread on a CEL related to my o2 sensors/catalytic converter here: http://www.bobistheoilguy.com/forums/ubbthreads.php?ubb=showflat&Main=184619&Number=2781610
But the problem has blossomed. Long story short, I replaced my converter and o2 sensors back in October to cure a cel. This was my second converter purchase, after buying a cheap one in 2009 that, as I discovered, burned up somewhere along the way.
Anyhow, when I first replaced my converter back in 2009, I snapped one of the bolts when putting the new one on. I took it to a neighborhood garage to fix. Flash forward to my recent repair job and shortly after slapping on the new converter, I noticed what I thought was a slight exhaust leak. I wasn't getting CELs but I thought I was hearing a random leak when shifting. So I bought new spring bolts (and nuts!) for the flange where the converter mates up to the manifold. Only...I couldn't get them to fit right. Waaay too much effort to get enough of the bolt through to put a nut on.
So today I dropped it off at an exhaust shop to have them deal with it. They called me back and said there was nothing they could do, it looked like the part didn't fit right. I mentioned the previous history, which got an "aha!" out of the mechanic. I'd forgotten, until telling him, about the previous guys a few years back drilling out the old bolt. Seems they decided to do the same on the other side, for some reason, and so both sides require a nut to mate w/ the bolt. Only, stock bolts weren't meant for a nut, since there is a nut welded/incorporated into the exhaust manifold flange. So I was trying to push the bolts in well beyond their intended depth, which is why they wouldn't go.
So my question is this: Which would be the easiest way to proceed? By a new (used) manifold w/ original threads intact (online prices seem to range between $75-150), have someone remove current manifold and grind down existing nut "protrusions" for lack of a better word, or look for longer bolts that could be made to work???
The guy I took it to was afraid to "open a new can worms" by trying to rig things but would a better exhaust/muffler shop be more willing to do something? The space is too confined to try and grind on the flange while its on the car so the manifold would have to be removed for either grinding OR (obviously) for replacement... Blargh...I'm not used to having car troubles anymore...
I had an earlier thread on a CEL related to my o2 sensors/catalytic converter here: http://www.bobistheoilguy.com/forums/ubbthreads.php?ubb=showflat&Main=184619&Number=2781610
But the problem has blossomed. Long story short, I replaced my converter and o2 sensors back in October to cure a cel. This was my second converter purchase, after buying a cheap one in 2009 that, as I discovered, burned up somewhere along the way.
Anyhow, when I first replaced my converter back in 2009, I snapped one of the bolts when putting the new one on. I took it to a neighborhood garage to fix. Flash forward to my recent repair job and shortly after slapping on the new converter, I noticed what I thought was a slight exhaust leak. I wasn't getting CELs but I thought I was hearing a random leak when shifting. So I bought new spring bolts (and nuts!) for the flange where the converter mates up to the manifold. Only...I couldn't get them to fit right. Waaay too much effort to get enough of the bolt through to put a nut on.
So today I dropped it off at an exhaust shop to have them deal with it. They called me back and said there was nothing they could do, it looked like the part didn't fit right. I mentioned the previous history, which got an "aha!" out of the mechanic. I'd forgotten, until telling him, about the previous guys a few years back drilling out the old bolt. Seems they decided to do the same on the other side, for some reason, and so both sides require a nut to mate w/ the bolt. Only, stock bolts weren't meant for a nut, since there is a nut welded/incorporated into the exhaust manifold flange. So I was trying to push the bolts in well beyond their intended depth, which is why they wouldn't go.
So my question is this: Which would be the easiest way to proceed? By a new (used) manifold w/ original threads intact (online prices seem to range between $75-150), have someone remove current manifold and grind down existing nut "protrusions" for lack of a better word, or look for longer bolts that could be made to work???
The guy I took it to was afraid to "open a new can worms" by trying to rig things but would a better exhaust/muffler shop be more willing to do something? The space is too confined to try and grind on the flange while its on the car so the manifold would have to be removed for either grinding OR (obviously) for replacement... Blargh...I'm not used to having car troubles anymore...
