Hey

Went to install a turboback exhaust on my car today and when I was putting the downpipe in I got one of the bolts into the o2 housing and couldn't get the other one in. So decided to try taking the one back off and starting with the other one first. Well when I took it off I guess I cross-threaded because it became impossible to take off to the point it stripped the bolt. So now the downpipe is attached to the o2 housing with the one bolt and I am going to need to drop it and fix it.

Will I be able to remove the downpipe and o2 housing together? Or will I need to find a way to get the bolt out first?

 

you can probably do it if you have a decent amount of clearance under the car...however, it will be a huge PITA

 

I doubt you stripped it taking it out. Chances are you didn't use pb blaster and the bolts are rusty and seem very tight. I suggest before panicking you lower the downpipe and try threading in the bolt without the resistance of the dp pulling it back. Again make sure to use pb blaster this time or wd-40 for a little lubricant. It should be fine. Sometimes I really have to give it a push before the thread actually reaches. Give into account that you are compressing a spring at the same time.

 

For me it would depend on your skill level and how much time you want to spend. Working on cars sometimes if you cross thread a bolt and cant get it off, break it. After you break the bolt remove the two parts then tap both and make sure you have a nice thread to start with again. A good tap and die set are very expensive though. Use a good anti seize on any exhaust part due to the contraction of the metal during heating process. Also NEVER use cheap nuts and bolts bc of the metals they are made of.

 

Well it got to the point it was harder to take out then it was to break the bolt free the first time I removed the stock exhaust so I am pretty sure something screwed up and I stripped the sides on the bolt so there is no hope in saving the bolt. I ordered an o2 housing so I will be eventually cutting the bolt off but it will be really hard to do while its in the car hence why I was wanting to be able to remove it first. Maybe I will try drilling or grinding the bolt off. Yeah this is going to be fun!

And I used pb blaster on the car the day before I did this as well as today before starting.

 

Its unlikely you stripped a bolt coming out. I have never done that and I have worked on cars for almost nine years now. Do you have an impact hammer? That might solve the problem the quickest.

 

THE BOLT HEAD IS STRIPPED. There is no way to remove it at this point anyway. It does not matter if the threads are stripped. I have been working on cars for a long time now as well and I am not an idiot and I know what it feels like when a bolt binds up right before it breaks. Unfortunately this time instead of breaking it just stripped the bolt head. So no way to take it out without easyouting the bolt or drilling and retapping. I have a new o2 housing on the way so I only need to get the old o2 housing out right now with the downpipe attached or if that isn't possible I will need too find a way to get the bolt head off so i can slip off the downpipe then the o2 housing.

 

Vice grips and a torch might do it.

 

Yeah good call. I think the only problem would be getting the vice grips or pump pliers in there. Its a pretty tight space.

 

You can do it, I have faith.

 

take a dremel with a small grinding wheel and reshape the bolt head and wrench it out. i do this whenever I stripe a bolt and it works like a charm! sometimes u have to go one size smaller with the socket but it works fine. if u find ur in between sizes just carefully keep grinding til the next size down socket fits. good luck!

 

well, i have had to deal with this in the past. not exactly the same as your dilema. It sucks because its so tight in there, but if you are going to change out the 02 housing and can not get the downpipe off, you may just need to remove the 02 housing from the turbo with the DP attatched. I never had to do it that way so I cant recall if its going to be in the way or not. check my write up on the 02 housing install and then have a quick look from under the car and from up top to see if you will be able to get at all 5 fasteners with the manifold off the car. if you can just dont forget to unbolt the DP from the rest of the exhaust so it hangs free.

if you do get it all apart. cut that bolt and get to work drilling it out. I suggest stepping up in bits when drilling it out, start small and work you way up. use plenty of cutting oil to keep the bits from burning. once that is out. again plenty of cutting oil and work the tap with a drill on the slowest setting you can go without it locking up. drill a little and back it out. repeat until you are all the way tapped. you will be able to gradually increase the dilling speed as you run it all the way through, just make sure you keep it straight.

02 housing write up
https://www.evolutionm.net/forums/sh...ght=02+housing

 

Thanks for all the replies so far. I am hoping someone has specific experience with removing the o2 housing and downpipe at the same time? ALSO do you use the spring/bolts on the evo o2 housing or do they just have a stud setup with a bolt?

 

Weld a nut to the sheared bolt and use a socket wrench to remove it. If that doesn't work just remove the o2 housing along with the downpipe.

 

Sadly don't have a welder. Thanks for the suggestion though.