Replacing the exhaust on a D1

[Rover1]

I need to replace my exhaust on my D1-everything behind the catalytic converters. The union (two bolts) between the exhaust and the Cat is extremely rusty and don't think there is any way of removing the nuts without snapping off the screws. How do I go about doing this if the screws are going to snap off?
Thanks for any help...

 

[1995-Disco-I]

The Flange you are speaking of is joined by two bolts and not studs that attach them together...... so you can put other bolts in there..... or at least that is how mine is put together!....

 

[Rover1]

Thanks for the reply...If they are bolts, where can I buy them? I can only find the nuts on Rovers North...

 

[gardrover]

any hardware store, preferably grade 8

 

[MUSKYMAN]

the stock ones are studs but after they break off you can just drill holes in the plate and use bolts.

 

[Rover1]

One last question (maybe)...is there enough clearance on the stock vehicle to install the new genuine exhaust while on the ground? Maybe remove the left rear wheel?
Thanks again

 

[ptschram]

Thom is aprtially correct. The original fasteners are indeed studs, but they are held in by virtue of huge knurls that make it a real PITA to remove them.

I prefer to cut them between the two pieces of the flange and then use a cutting torch to remove the vestiges of the knurled portion. Whatever you do, do not attempt to drive them out as the impact can destroy the catalytic converter material.

I use 3/8-16 X 2-1/2" nuts and bolts and expect to cut them off in the future if I have to.

An air driven cut-off wheel works wonders for cutting them apart and allows for more control (IMO) than a sawzall.

Good luck, it sounds worse than it is.

Cheers,
PT

ps-go Borla,I'm really pleased with my Borla set-up.

 

[enjoi1968]

ps-go Borla,I'm really pleased with my Borla set-up.

x2

 

[Two Cold Soakers]

Yes, you can do it on you back in the driveway with the car on all four tires.

Painful, but possible. Ramps or jackstands would be nice.

 

[robertf]

Thom is aprtially correct. The original fasteners are indeed studs, but they are held in by virtue of huge knurls that make it a real PITA to remove them.

sledge hammer has worked every time

to the person recommending grade 8 bolts- you are probably over tigthening your exhaust if you think you need grade 8.

 

[Rover1]

Thanks again for all the help..hopefully the studs stay in place..I've been using WD40 on hte bolts for a few days in preparation for the replacement. Hope that helps a little.
Will post the results....