Header question.. how to remove rear bolts from header pipe?

[d1giPhux]

I need to replace the gasket between my header pipe coming off the engine, and the first catalytic converter. However, after looking at it, cant figure out how to get clearance to remove the rear header pipe bolts.

Here is what I'm looking at. I need to replace the gasket (#3) in between pipes #1 and #2:
https://sl-i.net/FORUM/images/imported/2012/03/exhaust_gasket1-1.jpg

Here is the clearance issue on the header bolts that connect it to the cat converter:
https://sl-i.net/FORUM/images/imported/2012/03/exhaustF1-1.jpg

https://sl-i.net/FORUM/images/imported/2012/03/exhaustF2-1.jpg

I'm sure someone has done this before while removing their header pipe.. whats the trick? Looks like the tranmission is in the way, or is it just the annoying heat shield? If i remove the heat sheild.. its toast. The bolts are so rusty I doubt it would ever go back together.

Need some help! Thanks. :smt023

[StatGSR]

probably just the heat shield in the way making it look harder. did you even try loosening the nuts without putting anything on the other side?

[d1giPhux]

Nope.. didn't try. Looks like they would just spin around since its just a bolt / nut. I'm trying not to round these bastards off too, and I have a habit of doing that on the first try. Soaking them in PB and gonna wire brush them as well.

Anyone else ever done this? Really don't want to drop the rest of the pipe, as I'm not even sure that would do anything.

If i pull the heat shield off.. like i said, its toast. I wont be having a heat shield any more. If i have to do it.. i will. But I'm waiting for someone to confirm who has pulled this section off before.

Thanks.

[phi11]

I just snap them off, did you get new bolts?

[Reason]

I just snap them off, did you get new bolts?

Yep, this is the best way. You would probably replace the bolts anyway.

[chuckthefuk]

if you have air tools

This
http://www.gedoretools.co.uk/2190699-5345-thickbox/gedore-dg-20-9mm-swivel-socket-1-4-ud-profile.jpg

Plus this
https://sl-i.net/FORUM/

If you don't have air tools
This
https://sl-i.net/FORUM/

Plus this
https://sl-i.net/FORUM/

:-D

[d1giPhux]

I could snap them off and buy new bolts..but how can I tighten down the new bolts if there is no clearance on one side?

Chuck: I have an electric impact.. i could least get 1 side with it.

Does anyone know if I need to remove the stupid heat shield.. or is there another way to get clearance on the far bolts?

[StatGSR]

did you try to get a wrench in there? if you can't then yes you need to remove the heat shield. not like you need those heat shields anyway, all they do is add rattles...

[chuckthefuk]

Just take some side cutters (wire cutters) and clip a bit of the heat shield off.

I hate these things. they rust.. they rattle they are sharp.. remove them if you want...

Honestly for the amount of trouble this is giving you drop the entire exhaust with some help from a friend..

Unbolt the 4 x nuts from the heads, unhook the exhaust hangers and disconnect the o2 sensors.. Its pretty straight foward and you can also change the other gaskets while you are at it.

-Chuck

[d1giPhux]

Nah.. def don't wanna drop the entire exhaust.

I just started doing this.. so it hasn't given me any trouble yet.

Got one bolt loose, just need to get access to the other one. I think I may cut a bit off the heat shield or just remove it all together. I can get a wrench on one side of the hard-to-access bolt, however I can't get one on the other to stop it from spinning.

I'll report back after I try some more stuff.

[d1giPhux]

Nice! Got those bastards off. Used the following:

On the easy to get bolt: 13mm 6pt wrench / 12mm socket + wrench

On the hard to reach bolt: (12mm) 6t socket to hold it, and 13mm deep socket + universal impact joint + elecrtic impact

Now to see if I can even GET the new gasket in place. Gonna grab some new bolts too.. but glad I didn't destroy these!

[chuckthefuk]

:smt023

[d1giPhux]

The real question is.. hope i will be able to slip the gasket in between the 2 pipes and then tighten them back up. Seems like it could be even more complex then pulling this bastard apart. Also, my new gasket has a lip, and not sure exactly which way to fit it or which way will point towards the front of the car:

https://sl-i.net/FORUM/images/imported/2012/03/gasketlip2-1.jpg

https://sl-i.net/FORUM/images/imported/2012/03/gasketlip1-1.jpg

It will probably make more sense though when I clean the old one out.. but does anyone know off hand?

[d1giPhux]

Everything is removed now.. so thats the good part! :smt023

But now for the bad part. Couldn't find ANY bolts to match the ones that fit at ANY hardware stores. They look like they are between a size 8 and 10 metric, but not sure. Went to stealership and paid $22 FREAKIN dollars for 2 bolts and nuts. THEY didn't fit either (subaru exhaust bolt & nut). They are too wide. I need a bolt that is thinner. Least i got my $22 back.

Now i need to find something that fits. Not sure what the hell will work.. gonna have to do some serious searching. Its never easy it seems! LOL Hope I dont have to order something special from McMaster or something.

[02_Legacy]

The bolt size itself doesn't matter, just get the biggest one that fits into the hole.
As far as the lip on the gasket, I did my headers at school and I had the same question. I asked the instructor and after lots of looking at the gasket and both flanges we came up with the opinion that it doesn't matter. No leaks for me right now so either we got lucky and put it the right way or it really doesn't matter. This probably doesn't help you much but I thought I would share.

[d1giPhux]

Thanks for info. Yeah, I'm not really sure which way to put the gasket. I think it may have something to do with one side of the gasket crushing into place? I'm not really sure. Anyone got any more info possibly?

[StatGSR]

it doesn't matter which direction the gasket goes

[Wiscon_Mark]

I used a 10mm x 1.25 pitch which is exactly stock. Bought 'em at autozone. Wish the hardware store was open, they would've been a lot less expensive.

[Reason]

Bolt size doesn't matter. All you need is a bolt, washer, nut combo x2 that fits. Once tightened it wont go anywhere. As for the gasket its not directional, its just a gasket. Put it inplace and tighten it down.

[d1giPhux]

Mark: Yeah.. i picked up that size, and for some reason they wont fit. I guess the aftermarket cat I bought a while back has a smaller hole than stock. Gonna try cleaning everything up real good today and see if I can get it to fit. If not, maybe I can ream out the hole a bit, but that seems un-necessary and a bit scary to be doing on exhaust parts that cost so much. I'm sure I can get something that will fit, so its not a huge deal.

Thanks for the help guys! I'll let you know how ti sounds once everything is installed :smt023

[Huffer]

Use a wire brush on the existing bolts, then hit them with some PB blaster when you reuse them.

[d1giPhux]

Its all set! Gasket is installed and back to being 'quiet'. Yeah right.. I haven't driven this monster of a car in weeks. Been using my beater and WOW this thing has WAY more personality! :smt023 :smt020

I ended up using some SAE bolts I got at the hardware store. 5/8"? Not sure. But you use a 9/16" wrench to tighten them down.

Here are some pics of the final finishing touches.

Bolts removed, and old exhaust gasket still in place:
https://sl-i.net/FORUM/images/imported/2012/03/exhaust_finished1-1.jpg

OLD exhaust gasket cleaned off both surfaces:
https://sl-i.net/FORUM/images/imported/2012/03/exhaust_finished2-1.jpg

New gasket and bolts in place:
https://sl-i.net/FORUM/images/imported/2012/03/exhaust_finished3-1.jpg

https://sl-i.net/FORUM/images/imported/2012/03/exhaust_finished4-1.jpg

Bolts tightened down and everything sealed up:
https://sl-i.net/FORUM/images/imported/2012/03/exhaust_finished5-1.jpg

NOTE: My old gasket came off the exhaust the following way:

FLAT SIDE OF GASKET > Facing towards header pipe surface

Lipped 'double' side OF GASKET > Facing towards catalytic converter.

[d1giPhux]

ARGHHHH! :smt013

After getting the front exhaust gasket all done.. OF COURSE the rear one fails and blows out! :smt021

So.. had to grab a new gasket from subaru, and luckily since I've already done this once, only took me about 30 mins to do the rear one! :smt025

Everything is all quiet now, so gonna drop it off the jack stands and give it a test drive. Hope its finally ALL quiet! :smt023

[d1giPhux]

SUCCESS! ITS ALL FIXED NOW!!!! :grin:

[Wiscon_Mark]

Good feeling, ain't it? I was so happy when the headers were welded - Car felt so much nicer :smile: