Help please!!!

[2KExplorerSport]

I'm replacing the exhaust on my 00 Explorer Sport and I've run into a problem getting the bolts out that connect the passenger's side cat to the exhaust manifold. Anyone got any tricks or suggestions? I've soaked the bolts numerous times with PB Blaster. They are rusted and I believe the original bolts. I can't get in close enough to cut the bolts with a sawzall and all I'm doing with the ratchet is rounding the heads off. HELP!!! I need to try to get this done ASAP so I can go to work tomorrow. Any suggestions are appreciated!

 

[2KExplorerSport]

bump

 

[96eb96]

bump

got heat? you can get mapp torches cheap at lowes. heat it up (around the bolt) and carefully spray with pb or use candle wax in the threads. If its rounded off you may need a good vise grip now.

 

[2KExplorerSport]

That was gonna be my next step. Thanks so much!

 

[marragtop]

Use a 6 point socket, not a 12. If it's already somewhat rounded, go a size lower and maybe switch from MM to SAE to get the tightest fit possible.

 

[2KExplorerSport]

I've been using 6 point sockets. There's just so much rust and crap that I can't bite onto it enough. I even tried hammering the socket onto the bolt and that didn't work either.

 

[robertoa1a]

It has to get red hot! Weld an other bolt or something to it. Cut it with a rose-bud. Let me guess, you have to pull the trans and didn't need any extra down time. If you can still drive it, take it to a weld shop in an industrial area and do the deed, or buy some home welding equipment with the money you saved.

Can you cut the bolt with a die grinder with the wheel half wore down?

 

[2KExplorerSport]

Finally got it with a die grinder. What a pain in the ass. The next question I have is about the O2 sensors. I picked up all new sensors from my local parts store and one of the upstream sensors was boxed incorrectly. Instead of having the upstream sensor (with the longer wire) it had another downstream sensor in the box. Does anyone know if this sensor will work before the cats anyway. The parts store doesn't have any more in stock and I need my truck for the morning. Are the sensors the same, just with different wire lengths?