Yesterday I decided to install my new Berk HFCs I started with some PB Blaster on all the exhaust manifold to cat bolts and then the y-pipe to cat bolts(very rusted worse off then i've see on even 10 to 15 year old cars) and waited an hour. I've done my own exhaust work before but I have never ran into bolts that were so rusted and damn near impossible to get off in my life! On the y-pipe to cat bolts I used a 3/8 ratchet then to a 1/2 neither would work. I tried to use a mallet on the 1/2 before I tried a breaker bar and that wouldn't get them off either. I tried everything before I decided to use a floor jack to move the ratchet enough to dislodge one of the four bolts. It was late by then and being under the car in 100+ degree heat for a long while I called it a day. Has anyone else ran into similar issues????

 

Air tools. It's the only way to do it safely without risking damage to the nut. When I put on my HR y-pipe, the cat nuts were rusted badly and I put an 18" breaker bar to them and I could tell I was starting to apply too much torque. I broke out my air tools and broke those things loose like they were nothing.

 

yeah i need to try on some other bolts with an impact wrench but one of the bolts was so stubborn I couldn't even get it off with air tools. So i had to use a floor jack to move the 1/2 it was ridiculous I'm gonna make an attempt agan and see what happens.

 

Yikes...hope I don't have the same problem when I install mine! Hopefully being an 07 means the bolts won't be as seized!

 

If the impact didn't do it, assuming it has some decent torque rating, then something else is going on. Might be time to bust out the sawsall and cut them off.

 

Yeah the toque spec on the impact wrench should have been good enough. I thought about using a sawsall with a metal blade too I was just afraid that the massive vibrations may mess up the o2 sensors since they are so close to the flange. Should I be alright?

 

You bring up a good point. Do you have access to a cut-off wheel? Hell, even a Dremel would work, but it would take a little more time.

 

I had this happen when I put my HR y pipe on, the bolts going to the cats I got off, but the 2 bolts going to my mid pipe were too bad, I took it to a muffler shop and they torched them then the air gun got them off

 

Yeah that's exactly what I did today! I decided against going through the rigged floorjack method and just torched them. The bolts were a little easier to get off this time. I installed them today and I am very impressed thanks for all your help guys!

 

This is the key. When I did my FI exhaust all the bolst came out like butter using a 1/2 air ratchet.