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Broken Exhaust Bolts - Damage Control Advice?

Discussion in '2nd Gen. Tacomas (2005-2015)' started by mjohn617, May 19, 2011.

  1. May 19, 2011 at 2:25 PM
    #1
    mjohn617

    mjohn617 [OP] Well-Known Member

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    I just started my clutch replacement and came into a problem. After plenty of penetration spray and soft touch, I have broken two bolts off at the catalytic converters and one just aft of the system at the two compression fittings.

    Does anyone have some advice on what I should do? I am thinking about cutting the rest of the bolts off and drilling out the broken pieces out...or just buying long tube headers and exhaust.

    I really don't want to drop that kind of money on new shit, but I also don't want to remove the exhaust manifold to properly drill.

    [​IMG]

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    THIS SUCKS!
     
  2. May 19, 2011 at 2:27 PM
    #2
    chris4x4

    chris4x4 With sufficient thrust, pigs fly just fine. Moderator

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    You should be able to drill them, then use a tap & Die set to extract the remaining part of the bolt.
     
  3. May 19, 2011 at 2:53 PM
    #3
    mjohn617

    mjohn617 [OP] Well-Known Member

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    I don't think I am going to be able to, I put pictures up, it's bad!
     
  4. May 19, 2011 at 6:29 PM
    #4
    Jerry Bear

    Jerry Bear Well-Known Member

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    Just drill out the bad ones and use a locknut and bolt instead.
     
  5. May 19, 2011 at 8:29 PM
    #5
    mjohn617

    mjohn617 [OP] Well-Known Member

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    Thanks guys, that was my first attempt, drill out and clean up with a tap.

    I spent two hours on these bolts with a grinder and drill trying to get the flange flush to start drilling. Unfortunately the shop I am working at is a military hobby shop and is a borderline shit hole.

    I brought all my tools but no grinder or drill. The shops one is shit, I cut the exhaust!

    So my next move is I guess TRD exhaust and maybe Doug Thorley LTH.

    [​IMG]

    [​IMG]

    [​IMG]

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    [​IMG]
     
  6. May 19, 2011 at 9:16 PM
    #6
    mjohn617

    mjohn617 [OP] Well-Known Member

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    So I am checking out TRD catback exhaust and it looks like it does not go all the way to the cats, can anyone validate this? Do I still use the stock Y-section between the cats and the collector....the one I just cut today :)
     
  7. May 19, 2011 at 9:51 PM
    #7
    chris4x4

    chris4x4 With sufficient thrust, pigs fly just fine. Moderator

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    Yes. It goes until the Y. You can get a URD "Pipe Bomb" (IIRC) and that will take the place of the peice you just cut.
     
  8. May 19, 2011 at 10:33 PM
    #8
    mjohn617

    mjohn617 [OP] Well-Known Member

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    Thanks Chris4x4, I did some searching tonight and found that pipe from URD...looks like the only company making these.

    I have had a complete exhaust on the back burner now for a while...ordered it tonight!

    I just ordered a TRD cat-back exhaust, Doug Thorley LTH and Y-pipe, should have an interesting next week. :D

    I guess I need to post up some pictures when all these goodies get installed?
     
  9. May 19, 2011 at 11:30 PM
    #9
    Disorderly

    Disorderly Well-Known Member

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    Next time use a torch to heat the manifold stud area until glowing orange. Try to avoid heating the bolt and use vise grips to turn the studs out.
     
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