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2007 Forester X
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8 Posts
Discussion Starter · #1 ·
Hello,

I'm trying to replace an exhaust flange that has rusted/rotted out (cat to midpipe). I didn't allow PB to soak long enough and both bolt heads were sheared off when trying to separate the flanges.

I've gone through several cycles of soaking the whole assembly with PB (spring bolt side and the side with the sheared bolts.) Wanted to get some feedback before attempting to remove the rest of the assembly.

Regards,
tbweng
 

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2013 Forester
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17 Posts
Maybe you can punch the bolt out? Possibly heat the flange around the bolt before hitting the bolt with the punch? I don't know the configuration of that bolt/spring setup. It looks like you sheared the bolt when trying to remove the nut?

Looks like it will be drill the bolt type situation, just don't break the bit off inside.
 

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2007 Forester X
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8 Posts
Discussion Starter · #3 ·
Yes, the bolt was sheared when trying to remove the nut.

I wondered too about trying to punch the bolt through toward the springs. Does anybody know if the flanges are threaded, or will those bolts slide through if they're punched?

The sheared bolts punched out toward the side with the spring bolts, and I was able to separate the midpipe from the post cat pipe.

The old donut gasket is corroded and seems fused to the pipe. What's the best way to remove the remnants of the old donut gasket to ensure a leak proof fit?

Also, the new gasket provided by the auto parts store (felpro 61106) seems too big for the pipe. It does not fit snugly even around the remnants of the old gasket. Did I get the wrong part?

Sent from my SM-G930T using Tapatalk
 

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2007 Forester X
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8 Posts
Discussion Starter · #4 ·
What's the best way to clean out the old donut gasket? I've chisled out a decent amount, just wondering if there was an easier method.
 
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