Need help with exhaust on my gf's car

onlycodered

onlycodered

Well-Known Member
#1
#1
Hey guys. Sorry this isn't about Mustangs but I need your help with figuring something out. My girlfriend has a 2004 Pontiac Sunfire on which I'm replacing the catalytic converter pipe and resonator pipe. I'm going to cut off the muffler and clamp it onto my new resonator pipe as well. So anyway, here's my dilemma...

I need to figure out how to remove the bolts on the flange where the headers and the catalytic converter pipe meet (picture below). There's a limited amount of space since it's on the back of the engine in this car next to the firewall. I tried using a breaker bar with a universal joint driver adapter to give me more flexibility but that didn't work. I'm just wondering if you guys have any ideas for how to remove these as I'm sorta stumped. I've thought about maybe even unbolting the entire header from the engine as those bolts are easier to access and then just wiggle the entire assembly around until I have better access to the flange bolts.


Any help is greatly appreciated!
 
T

the5.ohh

Well-Known Member
#2
#2
Um not too sure, did you spray some WD40 on the bolt before you tried to remove it? Maybe it needs to be sprayed with the WD40 to loosen it up, just a thought idk lol
 
T

T's Little Mach

Member Plus
#3
#3
The flange is threaded? Have you tried heat? That bolt won't come out willingly without heat. You need to heat the flange cherry red.

If you like I can come over and give you a hand with getting it apart.
 
T

T's Little Mach

Member Plus
#4
#4
The flange is threaded? Have you tried heat? That bolt won't come out willingly without heat. You need to heat the flange cherry red.

If you like I can come over and give you a hand with getting it apart.
 
ford20

ford20

Member Plus
Staff member
NYM Staff
#8
#8
I will triple the recommendation, just don't mix heat with the WD40 though. Then at the end of the day when you have busted knuckles go to your girl and show her the battle wounds and get your reward lol.
 
onlycodered

onlycodered

Well-Known Member
#9
#9
The problem is I can't really fit any kind of long-handed ratchet or breaker bar in that area to take the bolts off. I'm not even sure using air tools would work. I've got a friend who works at a shop that might be able to take a look at it so we'll see. I have soaked it in PB Blaster though and ran the car at idle to burn off any excess so I don't play with the possibility of a fire. That wouldn't be fun.
 
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