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Removing rounded exhaust bolt? #4558930
10/30/17 04:59 AM
10/30/17 04:59 AM
Joined: Sep 2013
Posts: 10,457
Indiana
dlundblad Offline OP
dlundblad  Offline OP
Joined: Sep 2013
Posts: 10,457
Indiana
The cat on my truck needs replaced, but it looks like I wasn't the first one who attempted it. On the exhaust side, 1 bolt broke off effortlessly, which tells me it had been broken for some time. The other 2 are completely rounded as is the 02 sensor.

Perhaps I could get a nut splitter in there? A few parts stores have them, but they have 1 star reviews. Thankfully the engine side bolts look fine, but they won't budge. I'll pick up a MAPP gas torch after work. 5 mins of heat per bolt should do the trick I hope.

Perhaps heat and my rounded bolt remover tools would do the trick. It just stinks because the bolts are sized between the 2 tools because they are missing material from being rounded and rusted. The one that I should be using for it hardly fits on whereas the next size up is too big.

So, anyone have any experience with a nut splitter and if so, what brands do you guys recommend?
Same with a decent set of rounded bolt removers. I've had great luck with my compact Sears set, but they aren't doing me much good on this job.

I really don't want to have to take it somewhere, but it is what it is.. They would probably use an oxygen-acetylene torch and get all 6 off effortlessly. Thanks everyone.


03 Jeep WJ 4.0 200k Castrol Edge 10w40 HM Fram XG16
02 Volvo S60 2.4T 177k M1 0w40 Mahle OX149D
97 Chevy Blazer 4.3 149k Rotella T5 10w30 Supertech ST3980

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4558947
10/30/17 05:47 AM
10/30/17 05:47 AM
Joined: Nov 2008
Posts: 3,157
Oshawa, Ontario Canada
JC1 Offline
JC1  Offline
Joined: Nov 2008
Posts: 3,157
Oshawa, Ontario Canada
I have the cheap nut splitter from Harbor Freight. Works OK for those rust exhaust nuts and bolts.


2015 Grand Caravan SXT Plus 5w-20 PPPP/Fram Ultra Filter
1997 Honda Civic CX 5w-30 Shell Conventional/Fram Ultra Filter
Re: Removing rounded exhaust bolt? [Re: dlundblad] #4558951
10/30/17 06:07 AM
10/30/17 06:07 AM
Joined: Dec 2002
Posts: 40,910
'Stralia
Shannow Online content
Shannow  Online Content
Joined: Dec 2002
Posts: 40,910
'Stralia
Grab a cold chisel, and start "tapping" the nut off the way that it would want to come off.

That will also act as a nut splitter, expanding it some.

If it's a bolt, it doesn't work well.

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4558967
10/30/17 06:34 AM
10/30/17 06:34 AM
Joined: Aug 2013
Posts: 2,531
Central Maryland
HangFire Offline
HangFire  Offline
Joined: Aug 2013
Posts: 2,531
Central Maryland
Originally Posted By: dlundblad
Perhaps heat and my rounded bolt remover tools would do the trick. It just stinks because the bolts are sized between the 2 tools because they are missing material from being rounded and rusted. The one that I should be using for it hardly fits on whereas the next size up is too big.

Some pictures would help. A lot of what you can try is determined by a.) access and b.) how much collateral damage you're willing to tolerate. In your case, since you are replacing the Cat, damage to the Cat won't matter.

If you can get in there with a drill, drilling it out is also an option. I bought a right angle air drill because that's the smallest package I could find, and some shorty left hand Cobalt bits. Doesn't have to be left hand twist, but exhaust components tend to be rock hard due to heat cycling so a quality bit is required.

Cutting/grinding off the bolt head is also an option, at least on exhaust systems where the head is holding things together, you don't have to worry about the rest of the threaded shank because it's threaded into the far side or a nut, and you can pull the pieces apart once the bolt head is gone.


Various musings: http://hangfire.net
Re: Removing rounded exhaust bolt? [Re: dlundblad] #4558977
10/30/17 06:53 AM
10/30/17 06:53 AM
Joined: Aug 2008
Posts: 18,669
Ontario, Canada
StevieC Online content
StevieC  Online Content
Joined: Aug 2008
Posts: 18,669
Ontario, Canada
Depending on the room you have you can use a thin cutting wheel on a pneumatic grinder to split the nut on the side.

If that doesn't work then heat and vice grips is another option.

Last edited by StevieC; 10/30/17 06:54 AM.

'18 Highlander - AMSOIL SS 0w20 / ATF / Severe Gear
'06 Santa Fe - 535,000km AMSOIL SS 0w30 / ATF (R.I.P)
Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559042
10/30/17 07:59 AM
10/30/17 07:59 AM
Joined: Jun 2002
Posts: 1,836
Texas
Bud Offline
Bud  Offline
Joined: Jun 2002
Posts: 1,836
Texas
Vice grips or nut splitter if possible.


2016 Honda Pilot EX-L with NAV.....Mobil 1 0w20 AFE and Ultra XG7317
Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559076
10/30/17 08:54 AM
10/30/17 08:54 AM
Joined: Jun 2002
Posts: 12,522
The Motor City
Kestas Offline
Kestas  Offline
Joined: Jun 2002
Posts: 12,522
The Motor City
One of the first expensive tool purchases I made 40 years ago was an oxy-acetylene kit chiefly for removing rusted bolts. It cost me a lot ($400), bought new in the pre-craigslist days. But it only made good sense, living in Michigan. I've had a lot of use from it. It saved me a lot of money by not having to take work to the shop.

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559108
10/30/17 09:34 AM
10/30/17 09:34 AM
Joined: Jan 2013
Posts: 1,846
Texas
WyrTwister Offline
WyrTwister  Offline
Joined: Jan 2013
Posts: 1,846
Texas
I have found , heat it as hot as you can get it , then spray with penetrating oil . I like PB Blaster .

Repeat as necessary . Seems like this helps get the oil into the little cracks and crevices .

Try to get it red hot .

You may have to sacrifice a socket . One that is small enough to have to hammer it on .

You may have already been suggested , the specialized socket that is designed for this task . that have cutting edges to " bite " into the nut .

Best of luck , :-)


Wyr
God bless
Re: Removing rounded exhaust bolt? [Re: JC1] #4559142
10/30/17 10:05 AM
10/30/17 10:05 AM
Joined: Nov 2009
Posts: 4,943
Houston, Texas
motor_oil_madman Offline
motor_oil_madman  Offline
Joined: Nov 2009
Posts: 4,943
Houston, Texas
Originally Posted By: JC1
I have the cheap nut splitter from Harbor Freight. Works OK for those rust exhaust nuts and bolts.


Don't tell the wife you have one of those. She might use it. Lol


2007.5 dodge cummins 6.7 liter. Chevron Delo400 15w40. 7000 mile or 250-300hr intervals.

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559179
10/30/17 10:33 AM
10/30/17 10:33 AM
Joined: Jun 2013
Posts: 298
sw ohio
willbur Offline
willbur  Offline
Joined: Jun 2013
Posts: 298
sw ohio
I got a snap on splitter. Works great if you have good access to the bolts you need removed. Very bulky.

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559236
10/30/17 11:53 AM
10/30/17 11:53 AM
Joined: May 2009
Posts: 249
Hawaii, USA
anndel Offline
anndel  Offline
Joined: May 2009
Posts: 249
Hawaii, USA
Vise Grips, Vampliers, bolt extractor, etc., would work.

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559258
10/30/17 12:33 PM
10/30/17 12:33 PM
Joined: May 2014
Posts: 1,234
Minnesota
philipp10 Offline
philipp10  Offline
Joined: May 2014
Posts: 1,234
Minnesota
A simple angle grinder with an abrasive wheel will cut those bolts off in seconds. Less than $20 at Walmart.

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559310
10/30/17 01:57 PM
10/30/17 01:57 PM
Joined: May 2013
Posts: 133
Peace valley, Missouri
Fitter30 Offline
Fitter30  Offline
Joined: May 2013
Posts: 133
Peace valley, Missouri
dremel with a cut off wheel split the nut on a angle

Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559369
10/30/17 03:12 PM
10/30/17 03:12 PM
Joined: Jan 2007
Posts: 17,501
Clovis, CA
Merkava_4 Offline
Merkava_4  Offline
Joined: Jan 2007
Posts: 17,501
Clovis, CA
You need a Flank Drive Plus wrench. grin


Re: Removing rounded exhaust bolt? [Re: dlundblad] #4559646
10/30/17 08:09 PM
10/30/17 08:09 PM
Joined: Nov 2009
Posts: 34
OK
royesses Offline
royesses  Offline
Joined: Nov 2009
Posts: 34
OK
Channellock 410 "Nutbusters" pliers if there is room. A good nut splitter also may work.

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