Bottom Down-pipe bolt rounded off while attempting to install SW 3”down pipe

[chattanoogamav]

Here’s a first probably . Got my down pipe stuck on turbo on my 22 ford XL . Rounded off the bottom nut and stud. No way to get anything on it with out pulling PTU. Tried pulling turbo but two oil line bolts on the bottom pick up turbo lines are inaccessible because of PTU. Top it off my garbage Compressor stopped working so can’t cut it off with angle grinder. nothing else will fit up in there to break it loose. I feel like I’m delaying the inevitable of having to pull the PTU. And pretty sure no one is willing/able to help me out here. So this is Just a cautionary tale. Before you change your down pipe make sure to have a good set of extractor wrenches.

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[Automan21]

Damn I’m about to do mine and this isn’t helping my anxiety about it lol.
When I did my subie I sprayed the bolts/nuts with pb blaster the day before, drove it around and sprayed again the next morning. That afternoon I drove it enough to heat up the nuts then they came off easily. If I was closer I’d give you a hand and compressor loaner. Good luck

 

[EONR24]

https://www.amazon.com/Splitter-Sep...ocphy=9192488&hvtargid=pla-2281435177858&th=1

I would first try some vice grips. if that doesn't work buy one of these nut splitters. If you go at it with an angle grinder, you'll cut into the stud and will have to replace the stud as well..

 

[chattanoogamav]

https://www.amazon.com/Splitter-Sep...ocphy=9192488&hvtargid=pla-2281435177858&th=1

>I would first try some vice grips.

vice grips fit but the fire wall doesn’t give you enough space to break it loose

> if that doesn't work buy one of these nut splitters.

Nut splitter won’t fit in between the Cat and the stud

>If you go at it with an angle grinder, you'll cut into the stud and will have to replace the stud as well..

I under stand I have exhausted all means possible with out pulling the PTU or destroying anything.

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[chattanoogamav]

Damn I’m about to do mine and this isn’t helping my anxiety about it lol.
When I did my subie I sprayed the bolts/nuts with pb blaster the day before, drove it around and sprayed again the next morning. That afternoon I drove it enough to heat up the nuts then they came off easily. If I was closer I’d give you a hand and compressor loaner. Good luck

i started this on Saturday after driving around for about an hour to get the exhaust hot. I also took a torch to the bolts. The top two came out relatively easy with a 1/2 in breaker bar with 16mm socket. The lower bolt cannot be taken out as easy. Granted I blame my garbage freight 16mm wrench, but This is an inherently bad design on fords part and I am going to let them know about it.

 

[EONR24]

You could also try hammering on a slightly smaller socket or wrench. 5/8 wrench is slightly smaller than a 16mm so that could work. Another option is, if you have a welder, tac welding a slightly oversized wrench to break it free I realize the space is tight but there are a number of options to try.

 

[Automan21]

i started this on Saturday after driving around for about an hour to get the exhaust hot. I also took a torch to the bolts. The top two came out relatively easy with a 1/2 in breaker bar with 16mm socket. The lower bolt cannot be taken out as easy. Granted I blame my garbage freight 16mm wrench, but This is an inherently bad design on fords part and I am going to let them know about it.

I thought one of the top bolts were going to be a pain.

 

[chattanoogamav]

I thought one of the top bolts were going to be a pain.

Top bolts are the easy ones. You can get both of the bolts out from the top with long extensions. You have to shove your arm up under the engine between the turbo and cat for the bottom bolt

 

[chattanoogamav]

You could also try hammering on a slightly smaller socket or wrench. 5/8 wrench is slightly smaller than a 16mm so that could work. Another option is, if you have a welder, tac welding a slightly oversized wrench to break it free I realize the space is tight but there are a number of options to try.

There is no way to get anything in there besides a standard wrench. A socket will fit. Welding any thing to the nut would be nightmare even then there’s no turning the nut free because the firewall is in the way. You would have to keep re welding it every 1/4 turn lol

 

[Bad_Bob]

I would try a flare nut wrench. Or a 6 point box end wrench before I got hasty. I have been there before, a broken bolt in a head will turn a 30 minute job into a 6 hour job.

 

[shrek]

ALWAYS USE 6pt on exhaust. ALWAYS!

12pt will do this to you every....... single....... time....... Use IMPACT sockets as well.

 

[Solaryellow]

You can't get anything over the stud?

 

[NY DIY GUY]

Removing that bolt was a pita when I installed my stainless works Downpipe. I removed the top Ptu shield (4 bolts) to gain more access to that bolt. I then used the close end of a 16mm wrench and put it on that nut good and used a 2 foor bar on the open end of the wrench. Then just gave it a couple of taps to break it loose. Then I used a flex head 16 to take it off once I broke it loose. Fyi you need to take off both O2 sensors to get it out once you get that nut off. Your better off taking it out now before you take that nut off. Good luck

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