pecivil

Trying to install a fabspeed catback on a 2010 Cayman base and ran into a big problem trying to unbolt the cat to pipe connection. 3 bolts, none of which have hex heads on the cat side to grab to try to undo, and the nuts on the pipe side are rusted and sockets wont grab em but will round them.

Am I missing a secret or is running a sawzall blade between the union to cut the bolts the only way?

TIA

Cman21

You could try soaking the rusted bolts & nuts with PB Blaster to remove the rust. Let them soak for about 20 minutes.
Good luck !

Cman21

HoBoJoe

If this doesn't work go ahead and cut them, they tend to break during removal and should be replaced during install.

BillC3

There are no bolt heads on the cat side because those are actually pressed-in studs.

I hate to say this, but in cases like this, it's usually best to get the nuts off any way you can and then replace the studs with bolts. The studs will usually snap off as soon as you can get a good grip on the nuts. Then, use an oxyacetylene torch, heat the stud heads red-hot and use a punch & hammer to push out the studs from the gasket side of the flange (push the studs towards the cat).

Even if you can get some of the nuts to come off without breaking the studs, you should still replace the studs.

pecivil

thanks for all the help! I will try PB blaster and if not then cut. The studs without hex heads sure seem like a dumb way to do this connection. Definitely will use hex head bolts when replacing.

mitch48

I just found this thread, so hope you have already gotten the bolts off. I had the same problem when removing my exhaust to do a clutch job last year. I broke some of the nuts off getting everything removed, but I ended up taking the header/cats off to get a good angle to drive the studs out with a hammer and punch. I heated them up with my propane torch and they popped off easily. I just replaced them with regular nuts and bolts.