2nd Gen Non-Engine/Transmission Exhaust bolts

[mattfrey]

HELP! I bought the DPP 4" exhaust kit -- but I can not get my old system off! The bolts where the turbo ends and the exhaust begins (connected with the flange) just won't budge!



I used my BIG pneumatic wrench and I couldn't get to the bolts. I used my SMALL pneumatic wrench and it wasn't powerful enough to knock them loose.



Any suggestions????



Thanks!

Matt

 

[Turbo Tim 1]

Have you soaked them with penetrating oil? Them there bolts have had a hot life, try soaking them for a couple days and then try again. I used a few extensions and got the bolts from the bottom.

 

[RT66DOC]

Try PB Blaster

 

[Tcolesanti]

Try a BIG breaker bar, with a couple of extensions from the bottom. You should be able to do one of two things, break it loose or snap it off.

 

[bmoeller]

Originally posted by RT66DOC

Try PB Blaster

Do this first. Squirt some on them every day for a few days on a warm engine. Helps it soak in. Came out easy for me doing this.

 

[PA95CTD]

Mine had 140k+ on them when i did my 4'' exhaust, the shoulders had gotten so thin that i knew they would snap as soon as i put a wrench on them. I soaked them with blaster then heated the turbo flange threads with a torch too almost red hot and they started to move. I had to work them back and forth as they would tighten up, also kept spraying them at the same time. The threads were undamaged when done. When i started i just knew i was going to pull the turbo before this job was finished, it has'nt been off as of yet. New bolts from the dealer are only a couple bucks a piece. High-temp never-seeze is the best thing for this area, go slow and take your time and they should come out.

 

[Dieselnutz]

Like others said! PB and the loosen and tighten method!

 

[mattfrey]

Thanks everyone! I'll give it a shot and get back to you.



Matt

 

[mattfrey]

Hey Guys!



As you suggested, I soaked the bolts with PB Blaster for three days while the engine was warm. With a couple of extensions, I was able to get to the bolts from the bottom and they came right out.



I then had to hack saw the old system in half so I could get it out (it just wouldn't make the turn with the skid plate in the way).



Once I got the old system out, the new one installed in about 30 minutes. It lines up PERFECT with the factory mounts. I was very impressed. I love the sound as well. Really not much louder than factory.



Does anyone happen to know the specs of the bolts that connect the exhaust up to the turbo? I got a little carried away with the wrench and rounded off the head of the bolt just prior to getting it 100% snug. Ruined an otherwise perfect install.



Thanks again for the advice!



Matt

 

[Thomas]

. . . the specs of the bolts that connect the exhaust up to the turbo . . .

P/N 6100940 BOLT, Hex Flange Head, M10x1. 5x50

 

[mattfrey]

Thanks, Thomas!