Good evening all, I have been having a problem with my cat. convertor, it is rattling really bad, so I bought a direct replacement, I had already got a idea what i was in for but I tried to unbolt it and the bolts are just breaking off (I did soak them first) so I figured that I could just cut them and use the bolts that I got ahead of time but it seems like the cat and the muffler are welded togthere? Has anybody ran into this problem? any soultions? It is a 1999 4 dr 4x4.


thanks
Scott

 

Its hacksaw or sawzall time. Your gonna have to weld back together... if unable to do this yourself you may end up taking your truck and parts to a muffler shop.

 

On my (former) '96 most of the bolts snapped off as you describe, leaving the button head and spline shaft stuck in the flange. I used a mini cut off wheel to cut slots in each flange that were slightly wider than the bolt. Then drove the remaining part of the bolt out sideways with a punch. There was plenty enough meat of the flange remaining to hold the new bolts in place. I used standard bolts as replacements; not the button heads with flanged shafts that were factory.
The cutoff wheel was much smaller than a saws-all and I was able to work under the car without removing the exhaust -- but just barely enough space. And it cut off the nuts that were inaccessible to a long wrench. The cut off tool was >$20 and I already had compressed air and welding. But decided to re-bolt the flanges since there was plenty of metal to hold.
If a previous owner welded the flanges, you're likely in for a new muffler too unless you have a good torch. Old welds are nearly impossible to cut with a saw or wheel. Factory flanges weren't welded but do stick pretty good.
Good luck.

 

Just a quick insert? I know you can get special drill bits for drilling out welds is it possible to get something like for a reciprocating saw?

 

I ran a two inch tap-con screw right up the middle / bottom of the converter body and it stopped the rattle. Don't know if it will last but I'm hoping to luck out.