Help on removing the exhaust down pipe

[snowwolf]

Hi Guys..... I have now ordered a new down pipe for my 4.5 1996 as the old one has now got another hole in it.

Can anyone give me any tips on removing the down pipe from manifold and at the other end where the cat joins, other than keep spraying nut release every day for a few days, is there anything else to look out for and is it a very hard thing to do or best left to an exhaust company to do.

 

[Mickldo]

Hi Guys..... I have now ordered a new down pipe for my 4.5 1996 as the old one has now got another hole in it.

Can anyone give me any tips on removing the down pipe from manifold and at the other end where the cat joins, other than keep spraying nut release every day for a few days, is there anything else to look out for and is it a very hard thing to do or best left to an exhaust company to do.

I'm not familiar with FZJs as I have HZJ but I like to have a good single hex socket of the correct size on a long one piece extension. Crack the nut using a breaker bar from down underneath the rig. Less chance of smashing your knuckles or rounding off the nut.

 

[vasellers]

Just removed mine on my'88 FJ62. 248,000 miles neither downpipes or cats ever removed. PB Blaster for several days, down pipe nuts came right off. LONG extension for big socket wrench. Had to grind the bolt heads off the cats, so rusted couldn't get wrench or socket to hold.

 

[snowwolf]

Cheers for the infol, it's looking good that (fingers crossed) that they will come undone

I went to the local exhaust garage earlier and they put it up on ramps and said" ohhh noooo!!!) I said what? they replied

" Them nuts that are on the flange down pipes are a nightmare to get off, as they have a nyloc type nut which is not nylon but a metal lock type end on them and when you try to undo they just grip the stud and sieze up"

To be honest, I was looking at the same time he was, and when I see the nuts, I was quite amazed how good they looked, not rusted at all and thought they would undo quite easily, the cat bolts looked like they will need grinding off tho..LOL which will not be a problem.

If anyone else has had any more experiences with the exhaust nuts, please add to this.....Thanks for the help, its made me feel a bit beeter about doing the job.

 

[wthrwrk]

removing nuts

Cheers for the infol, it's looking good that (fingers crossed) that they will come undone

I went to the local exhaust garage earlier and they put it up on ramps and said" ohhh noooo!!!) I said what? they replied

" Them nuts that are on the flange down pipes are a nightmare to get off, as they have a nyloc type nut which is not nylon but a metal lock type end on them and when you try to undo they just grip the stud and sieze up"

To be honest, I was looking at the same time he was, and when I see the nuts, I was quite amazed how good they looked, not rusted at all and thought they would undo quite easily, the cat bolts looked like they will need grinding off tho..LOL which will not be a problem.

If anyone else has had any more experiences with the exhaust nuts, please add to this.....Thanks for the help, its made me feel a bit beeter about doing the job.

I am having the same problem with one o2 sensor on my 94. The first one (Inner) i was able to replace in less than an hour. This second one i have tried to remove the nuts twice now using every tool I have, and buying a couple more. I soak it for days with PB blaster to no avail. I am about at the piont of taking it to a muffler shop and have them replace it for me. Nothing like spending $100 to replace a 50 cent nut.

 

[snowwolf]

sorry to hear your having probs getting the nut off, bet your cheezed off, to be honest I have only seen one oxy sensor on mine and that right next to the 1st cat, where is the other one?

 

[TX Cruiser]

I soaked them twice daily for 3 days. I still had to use an impact gun to get them off.

I really don't want to reuse them either, anyone know what size those nuts on the down pipe are? 3FE. I've been looking all morning for info to no avail, and my L/C and books are 200 miles away, so I can't exactly size them up.

Hopefully I can get you guys some pics of the engine install. It's been a fun project so far.

 

[tashby]

I am having the same problem with one o2 sensor on my 94. The first one (Inner) i was able to replace in less than an hour. This second one i have tried to remove the nuts twice now using every tool I have, and buying a couple more. I soak it for days with PB blaster to no avail. I am about at the piont of taking it to a muffler shop and have them replace it for me. Nothing like spending $100 to replace a 50 cent nut.

You could use a dremel type of tool and cut or split the nuts off of the studs and buy a die and clean up the threads. Just a trick that I learned from a good friend.

 

[KingOfFools]

sorry to hear your having probs getting the nut off, bet your cheezed off, to be honest I have only seen one oxy sensor on mine and that right next to the 1st cat, where is the other one?

Depends on what year and what emissions standards you have to meet. Assuming you have a 95-97, US spec is right behind the second cat. 93-94 they are right next to each other ( I assume you would have seen it). 3FE, not sure on that one. The UK specs may only require one though.

So I just re-read your first post (I should pay more attn). 96 should be just behind the second cat.