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#4558930 - 10/30/17 04:59 AM Removing rounded exhaust bolt?
dlundblad Offline


Registered: 09/30/13
Posts: 10058
Loc: 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 199k Castrol Edge 10w40 HM Fram XG16
02 Volvo S60 2.4T 177k M1 0w40 Mahle OX149D
97 Chevy Blazer 4.3 145k Rotella T5 10w30 Fram TG3980


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#4558947 - 10/30/17 05:47 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
JC1 Offline


Registered: 11/29/08
Posts: 3019
Loc: Oshawa, Ontario Canada
I have the cheap nut splitter from Harbor Freight. Works OK for those rust exhaust nuts and bolts.
_________________________
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#4558951 - 10/30/17 06:07 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
Shannow Offline


Registered: 12/12/02
Posts: 39927
Loc: '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.

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#4558967 - 10/30/17 06:34 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
HangFire Offline


Registered: 08/21/13
Posts: 2506
Loc: 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.
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#4558977 - 10/30/17 06:53 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
StevieC Offline


Registered: 08/21/08
Posts: 17116
Loc: 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.


Edited by StevieC (10/30/17 06:54 AM)
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#4559042 - 10/30/17 07:59 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
Bud Offline


Registered: 06/04/02
Posts: 1725
Loc: Texas
Vice grips or nut splitter if possible.
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#4559076 - 10/30/17 08:54 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
Kestas Offline



Registered: 06/04/02
Posts: 12343
Loc: 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.

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#4559108 - 10/30/17 09:34 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
WyrTwister Offline


Registered: 01/13/13
Posts: 1532
Loc: 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 , :-)
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God bless

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#4559142 - 10/30/17 10:05 AM Re: Removing rounded exhaust bolt? [Re: JC1]
motor_oil_madman Offline


Registered: 11/29/09
Posts: 4860
Loc: 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
_________________________
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#4559179 - 10/30/17 10:33 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
willbur Offline


Registered: 06/06/13
Posts: 288
Loc: sw ohio
I got a snap on splitter. Works great if you have good access to the bolts you need removed. Very bulky.

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#4559236 - 10/30/17 11:53 AM Re: Removing rounded exhaust bolt? [Re: dlundblad]
anndel Offline


Registered: 05/28/09
Posts: 245
Loc: Hawaii, USA
Vise Grips, Vampliers, bolt extractor, etc., would work.

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#4559258 - 10/30/17 12:33 PM Re: Removing rounded exhaust bolt? [Re: dlundblad]
philipp10 Offline


Registered: 05/09/14
Posts: 1184
Loc: Minnesota
A simple angle grinder with an abrasive wheel will cut those bolts off in seconds. Less than $20 at Walmart.

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#4559310 - 10/30/17 01:57 PM Re: Removing rounded exhaust bolt? [Re: dlundblad]
Fitter30 Offline


Registered: 05/05/13
Posts: 104
Loc: Peace valley, Missouri
dremel with a cut off wheel split the nut on a angle

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#4559369 - 10/30/17 03:12 PM Re: Removing rounded exhaust bolt? [Re: dlundblad]
Merkava_4 Offline


Registered: 01/30/07
Posts: 17501
Loc: Clovis, CA
You need a Flank Drive Plus wrench. grin


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#4559646 - 10/30/17 08:09 PM Re: Removing rounded exhaust bolt? [Re: dlundblad]
royesses Offline


Registered: 11/10/09
Posts: 33
Loc: OK
Channellock 410 "Nutbusters" pliers if there is room. A good nut splitter also may work.

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