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Originally Posted by eightsandaces
I know this is going to sound bad but I can't remember being more pissed in 51 years. I now have a helio coil in my exhaust manifold I'm praying will sock up and one more to repair I'm praying won't end up a second helio coil. Besides that, the uber strong, splined threaded bolts in the cat converter? Three came out like butter, the other three I beat the **************** out of no no avail. I have no idea how to get those lower splines out except to rent a torch.
I'm serious when I say I very well may have wrecked my car and I'm so defeated I may just sell it for a huge loss if I can't remedy the rest of the repair, all in pursuit of sound and maybe 10 hp...
Any suggestions on the splined broken bolts other than the torch I don't have would be appreciated.
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Eights:
Don't despair, it can be done. Those splined bolts can be drilled out if you are patient and use the right tools. I recently went through the exact set of difficulties and was able to successfully drill out all of the broken studs and later drill out the splined bolts on the catalytic converters. I replaced them all with stainless steel fasteners.
Here is a photo of the remnants of the splined bolts on the cats:
Note that it is not a good idea to bang them out with a sledge hammer as you may damage the cats.
Take a look at this thread, it may give you some useful tips and some inspiration:
http://www.ppbb.com/phorum/read.php?19,1552044,1552044#msg-1552044
Also take a look at this thread for some more text and photos:
http://www.ppbb.com/phorum/read.php?19,1551648,1551736#msg-1551736
The key in drilling out the bolts is using that little dremel carbide bit if you don't get your initial mark dead center.
Hang in there!
Regards, Maurice.