i've decided to go ahead with a self-muffler install, but some of the bolts connecting the pieces are seriously rusted (fused) together. any suggestions for loosening the bolts? am i silly to think a little wd-40 will do the trick?

thanks

Perhaps not silly, but just sold a pack of BS by the advertising. There have been plenty of discussions here about what does and doesn't work on this problem. The following products that board members have said work for them: Yield Rust Penetrant; P B Blaster; Sea Foam Deep Creep. You might try one of them and see if you have any better results. If not, try a sawzall or an angle grinder and just replace them.

you my try heating them up and turn them slow and see if they back out:confused:

heat them up, like with a small blow torch??

Depending on which bolts, but if you don't care about destroying the bolts/nuts, try a dremel tool with an edge cutting disk can cut a bolt or split a nut easily; just remember to wear safety glasses.

There is an art to dealing with corroded bolts. Look at all of the penetrants, special tools, heat etc. as a "bag of tricks". If one doesn't work, move on to another method.

 

Depending on what (if any) portions of the exhaust you want to save, you may consider dropping the exhaust from the Y back. With the exhaust off the car, it is much easier to work on the connections at the flanges, clamps, etc. Oftentimes, you'll be forced into the "y-back" scenerio anyway. Ever wonder why muffler shops guarantee the mufflers forever? Cause they can make up for their loss by selling you the rest of the exhaust system. If the system as a whole is badly deteriorated, don't get your hopes up too high. You'll waste a lot of time trying to take it all apart and end up replacing it anyway.

 

If you plan to replace the pipes and muffler (and possibly salvaging the cat) the fastest and easiest way is to take a sawzall to the main pipe on either side of the cat inlet and outlet flanges. Then, unbolt the first pipe off the y(resonator pipe). All the sections can now be removed from the undercarriage with no further unbolting.

 

With the cat on the bench, you have lots of options on how to remove the bolts cleanly and salvage the unit. A machine shop is also an option, and sure beats the cost of a new cat.

 

good luck, John