Exhaust removal tips
Thread Starter
Advanced
Joined: Aug 2008
Posts: 68
Likes: 0
From: Reston Va
Exhaust removal tips
I am getting ready to begin to remove the exhaust system to get access to the ZF rear seal. The bolts on the drivers side Cat look pretty rusted. Access is not very good either. Anyone have any tips for this task besides heat and tons of PB Blaster? I am concerned that the bolts will snap and I will have to replace the cats.
Thanks
Thanks
Melting Slicks
Joined: Mar 2008
Posts: 2,141
Likes: 76
From: Santa Maria, CA
On my 85, I was able to remove the bolts on the front Y to manifold collector, disconnect the midway strap and remove the rear brackets. The whole system came out in one piece. Not hard at all.
Pro
Joined: Jun 2008
Posts: 610
Likes: 1
I believe my 96 exhaust is similar to your 94 and that flange is indeed an area of concern. I think you're on the right path with heat. Get in there with a wire brush as best you can. For the top bolt you need a swivel and long extension.
If a stud breaks you can drill out the flange and thread it for a bolt.
I don't know how the clearances will be for your transmission. On an automatic it's tight at the oxygen sensor. I remove the sensor first and reinstall it after the exhaust is back in place. In any event don't forget to unplug the sensor.
If a stud breaks you can drill out the flange and thread it for a bolt.
I don't know how the clearances will be for your transmission. On an automatic it's tight at the oxygen sensor. I remove the sensor first and reinstall it after the exhaust is back in place. In any event don't forget to unplug the sensor.
Le Mans Master
Joined: Mar 2001
Posts: 7,999
Likes: 14
From: Life is just one big track event. Everything before and after is prep and warm-up and cool-down laps
Cruise-In III Veteran
Cruise-In IV Veteran
St. Jude Donor '12
The problem is going to be if there is a mount on the cat that attaches to the firewall area.
On my 92 I don't have that issue.
My manifold to cat bolts were very rusted and we were worried the first time. Lots of a PB blaster type fluid (I was doing at a friends house and he had something like PB blaster)
Lots of patience - Unscrew a trun, srcew in a turn, unscrew 1 1/2 turns, etc.
They eventually came off with no broken studs. Had them on and of probably a dozen times since then with no issues.
On my 92 I don't have that issue.
My manifold to cat bolts were very rusted and we were worried the first time. Lots of a PB blaster type fluid (I was doing at a friends house and he had something like PB blaster)
Lots of patience - Unscrew a trun, srcew in a turn, unscrew 1 1/2 turns, etc.
They eventually came off with no broken studs. Had them on and of probably a dozen times since then with no issues.
Race Director
Joined: Feb 2003
Posts: 11,671
Likes: 20
From: Lake Wylie SC
It's not the end of the world if they do brake. They broke on my 92 and I wound up taking the headers off. While I was in there, I replaced them with real headers and I have been pleased ever since. Besides, the new headers look much better and sound much better. They also reduce the heat under the hood. Again, While you are in there, replace your fuel filter as it will be much easier to get at.
Burning Brakes
Joined: Oct 2009
Posts: 773
Likes: 2
From: Minneapolis MN
I am getting ready to begin to remove the exhaust system to get access to the ZF rear seal. The bolts on the drivers side Cat look pretty rusted. Access is not very good either. Anyone have any tips for this task besides heat and tons of PB Blaster? I am concerned that the bolts will snap and I will have to replace the cats.
Thanks
Thanks
If not wanting to listen first try tightening bolt/nut slightly,then trying to loosen.Or "shock" bolt by hitting with hammer then try tighten then loosen slowing.Hope this helps.
Burning Brakes
Joined: Oct 2009
Posts: 773
Likes: 2
From: Minneapolis MN
I am getting ready to begin to remove the exhaust system to get access to the ZF rear seal. The bolts on the drivers side Cat look pretty rusted. Access is not very good either. Anyone have any tips for this task besides heat and tons of PB Blaster? I am concerned that the bolts will snap and I will have to replace the cats.
Thanks
Thanks
& very knowledgeable.Just understand,make sure you have proper tools(rent,bring somewhere to someone who has) or you will learn the hard way like I did but I guess thats where you get experience.
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Top 10 Corvette Engines RANKED by Peak Torque (70+ Years of Muscle!)
Joe Kucinski
Corvette ZR1X Will Be Pacing the Indy 500, And Could Probably Race, Too!
Verdad Gallardo
Top 10 Corvettes Coming to Mecum Indy 2026!
Brett Foote
Top 10 C9 Corvette MUST-HAVES to Fix These C8 Generation Flaws!
Michael S. Palmer
10 Revolutionary 'Corvette Firsts' Most People Don't Know
Joe Kucinski
5 Reasons to Upgrade to an LS6-Powered Corvette; 5 Reasons to Stay LT2
Michael S. Palmer
