Simple Saturn Tailpipe Q

[Steve W.]

Hi,
Mid-way down the car, at the tail end of the catalytic converter, there are
flanges and 3 bolts on my '95 Saturn SW1. If they were nuts at some point,
I couldn't tell you, but whatever's left has to come off, because the oil
pan is coming out. Just curious, what do you use when replacing these bits
of old fasteners?

TIA -

Mark

Could be bolts into nuts or bolts into a threaded hole in the flange.
Either way if your pulling it apart just grind both sides clean and then
install new bolts and nuts, along with a new flange gasket.

 

[Mark G. Meyers]

Hi,
Mid-way down the car, at the tail end of the catalytic converter, there are
flanges and 3 bolts on my '95 Saturn SW1. If they were nuts at some point,
I couldn't tell you, but whatever's left has to come off, because the oil
pan is coming out. Just curious, what do you use when replacing these bits
of old fasteners?

TIA -

Mark

 

[Mark G. Meyers]

Hi,
As I get more of the rust off, it looks like bolts that run through from the
converter side, and on the back side, the flange itself is threaded to
receive the bolts. Those don't look like nuts or ordinary bolts - the bolts
themselves taper to really twiggy ends (all 3).

So it looks like I might be supposed to try to save the threaded (receiving)
flange, and maybe just cut the bolt heads off and unscrew and replace the
bolts, but those bolts also look pretty well rusted/fastened to the
receiving flange threads. One of the bolt heads is also impossible to reach
with a power tool (the one on top).

- Mark

 

[Mark G. Meyers]

Well, I went ahead and did what I could, which is cutting everything all
off.

Now according to the parts guy at Saturn, and I was guessing the same, this
was supposed to be nuts and bolts - it isn't. The flange on the converter
side has bolts welded right in there, it appears. I have cut the heads and
tails off, and I am going to have to drill out those holes.

Right now, I don't have drill bits/drill that can do it. Perhapos I can
find a shop with a drill that can?

Cheers -

Mark

 

[Noozer]

Well, I went ahead and did what I could, which is cutting everything all
off.

Now according to the parts guy at Saturn, and I was guessing the same,
this
was supposed to be nuts and bolts - it isn't. The flange on the converter
side has bolts welded right in there, it appears. I have cut the heads
and
tails off, and I am going to have to drill out those holes.

Right now, I don't have drill bits/drill that can do it. Perhapos I can
find a shop with a drill that can?

Take it to a muffler shop and have them torch it off, and then tape/wire it
together for the trip home.

 

[Nate Nagel]

If the bolts were welded to the flange, they were probably welded at the
heads. Try grinding the heads off right down to the flange with a die
grinder or 4" angle grinder if you have one and then drive the shanks
out with a round punch and BFH. If the welder was really good and got
lots of penetration you may end up having to drill though. Get NEW HSS
drill bits and have a friend spray some oil on the bit while you're
drilling. low-ish speed, a high torque (1/2" chuck) drill, and a
reasonable amount of pressure seems to work best with hardened bolts.
Drill bit may last only a couple of bolts. Drill a small pilot hole
first and then go to the through hole size. replace bolts with
stainless ones with lots of anti-seize Dressing the flange (I assume
it's flat) with a flat file before installing a new gasket will help it
seal better.

good luck

nate

Well, I went ahead and did what I could, which is cutting everything all
off.

Now according to the parts guy at Saturn, and I was guessing the same, this
was supposed to be nuts and bolts - it isn't. The flange on the converter
side has bolts welded right in there, it appears. I have cut the heads and
tails off, and I am going to have to drill out those holes.

Right now, I don't have drill bits/drill that can do it. Perhapos I can
find a shop with a drill that can?

Cheers -

Mark

 

[Mark G. Meyers]

Nate,
Sounds to me like you're speaking from experience on all counts. These
bolts were welded in pretty nicely, because I can't find the place where the
head leaves off and the flange begins. BFH- I'll remember that!

Thanks -
Mark

If the bolts were welded to the flange, they were probably welded at the
heads. Try grinding the heads off right down to the flange with a die
grinder or 4" angle grinder if you have one and then drive the shanks
out with a round punch and BFH. If the welder was really good and got
lots of penetration you may end up having to drill though. Get NEW HSS
drill bits and have a friend spray some oil on the bit while you're
drilling. low-ish speed, a high torque (1/2" chuck) drill, and a
reasonable amount of pressure seems to work best with hardened bolts.
Drill bit may last only a couple of bolts. Drill a small pilot hole
first and then go to the through hole size. replace bolts with
stainless ones with lots of anti-seize Dressing the flange (I assume
it's flat) with a flat file before installing a new gasket will help it
seal better.

good luck

nate

 

[N8N]

I'm used to working on cars 40 years older than your Saturn, so I am
no stranger to drilling out busted bolts

I can, however, state that I have successfully drilled out bolts in
blind holes using a hand drill without having to use a Helicoil.

I guess I should put that on my resume

nate