post #946 of Old 02-15-2012, 03:58 PM Thread Starter
djflyy
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So today I intended on installing my new exhaust. That didn't get far. All that remained on the Jeep was the dilapidated catalytic converter and front pipe, held on by ONE of the flange bolts at the header, and a bunch of bailing wire along the frame back to the transfer case. I went out a few times over the course of the morning and soaked the bolts in PB Blaster, as well as the external bolts of the O2 sensors to make removal easier. This did nothing.

The bolt head at the header flange snapped clear off, leaving whatever is on top of the flange to be rusted onto the header flange side. The other one was not securing anything, and still remains in a small form, ready to snap off if I attempt to remove it. Also, the O2 sensors would not budge an inch. I released the clips from the engine harness and removed the cat pipes anyway just to get them off. This may end up being a bad idea, as now when I run it I'll get a CEL for the lack of O2 sensors.

Either way, I'm on a tight time table to get this re-installed. If anyone has a thought on how, please let me know. Also... how do I go about routing the new muffler/cat-back portion through the track bars? Jack up the frame and let the suspension drop?

Thoughts appreciated.













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post #947 of Old 02-15-2012, 07:00 PM Thread Starter
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Bump for thoughts...
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post #948 of Old 02-15-2012, 07:22 PM
2003X
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Originally Posted by djflyy View Post
Bump for thoughts...
Any way to get a drill in there to drill out the bolt on the header pipe?
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post #949 of Old 02-15-2012, 08:16 PM Thread Starter
djflyy
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Originally Posted by 2003X View Post
Any way to get a drill in there to drill out the bolt on the header pipe?
I had thought about that, and doing it after grinding down what's left of the bolts... but the area in there is rather tight and I'm not sure I could fit the bit and drill without screwing it up. It would have to be done from below 'cause I don't think there's enough room from above.
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post #950 of Old 02-15-2012, 09:22 PM
Kenbo-Slice
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cut the stud, grind it flush, center punch, drill, use a nut and bolt.

It's tight, it will suck and you will probably swear a lot but it is doable. Good luck.
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post #951 of Old 02-15-2012, 09:25 PM Thread Starter
djflyy
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Found this. Walker Exhaust's "Flange Repair Kit" for $20.00 - meaning all I'd have to do is remove the existing one, or at least grind it down a little to clean the installation up. Might just be worth it, and Advance Auto carries it in stock locally.


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post #952 of Old 02-15-2012, 09:27 PM
Kenbo-Slice
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As for the o2 sensor, heat the thread bung on the old downpipe (hold the wires out of harms way) until it's cherry and it should come right out.
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post #953 of Old 02-16-2012, 07:59 AM
2003X
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Quote:
Originally Posted by djflyy View Post
Found this. Walker Exhaust's "Flange Repair Kit" for $20.00 - meaning all I'd have to do is remove the existing one, or at least grind it down a little to clean the installation up. Might just be worth it, and Advance Auto carries it in stock locally.


I like that idea.
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post #954 of Old 02-16-2012, 09:51 AM
CrawlingForward
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I can bring over my grinder and a couple of wheels when I drop off your jacks and wheel chock, if you'd like!

Let me know!

My Other Jeep Is A Jeep - Crawlingforward's Jeep-Related Adventures

95 YJ, Rio Grande - The Wannabe Sleeper Wheeler
2010 JKU, Islander Edition - The Burly Stock Overlander

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post #955 of Old 02-16-2012, 10:13 AM Thread Starter
djflyy
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Originally Posted by CrawlingForward View Post
I can bring over my grinder and a couple of wheels when I drop off your jacks and wheel chock, if you'd like!

Let me know!
Absolutely... I'm going to try and work on it now. Shoot me a text
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post #956 of Old 02-16-2012, 03:13 PM Thread Starter
djflyy
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Did surgery today on the header. I went by Advance this morning and picked up the Walker flange kit, a 2.5" exhaust clamp, and a bottle of MAPP gas to torch the old O2 sensors with. Then a quick stop at Lowes to get the additional hardware I needed.

Once I got home, I took out the grinder and cut off the old flange pieces from the header. It was extremely cramped in there, and it took a lot of moving to keep myself out of the way of the sparks (even with goggles on). After they were cut off, I swapped to a thicker disc and ground down what was left of the pieces. I ended up having to grind down the flange kit as well to get it to fit onto the header. Then it was a matter of bolting it up, and tightening it down. I was sure to put Anti-Seize on everything.

Bolted up the cat to the front pipe, and was done with step 1! Unfortunately I couldn't separate the muffler from the tail pipe by myself so I had to stop there for the day. Even with the rear end jacked up, I just couldn't finagle it over the rear track bar so it wouldn't sit.

All that's left is getting the muffler in, and ordering new O2 sensors. Torched the hell out of these ones and they didn't budge. Rust, carbon build up, no-budge. New ones on Amazon are $75 for both from Prime, so I'll have to do that soon I guess and just won't be driving the Jeep till they're around.

Thanks for the help guys.







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post #957 of Old 02-16-2012, 03:14 PM Thread Starter
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post #958 of Old 02-16-2012, 05:13 PM
Cowboyup94
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Hey Kenbo, I don't mean to change the subject on djflyy's build but I just read your build about your dually. It was like reading a story from grade school of excitement, excitement, and more excitement and then the most gut wrenching thing happens... Killed me man of what condition it was in, just amazing!

NOW BACK TO DJFLYY'S BUILD! SORRY!
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post #959 of Old 02-16-2012, 05:47 PM
Kenbo-Slice
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Haha, thanks Cowboy. It was unfortunate for sure.... I miss that big *** truck (not the 7mpg, haha)

I barely scratched the surface of what I was going to do to it. It definitely sucked. Thanks for the kind words!

Okay, hijack over!
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post #960 of Old 02-16-2012, 06:09 PM
Cowboyup94
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Yessir. It sounded awesome. Djflyy, How did you make out with those O2 sensors? I had a heck of a time with the one on my WJ.
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