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Nevalite
04-08-2013, 06:49 PM
Hello,

I need to replace my down pipe because the flex joint failed and I was just looking for any tips on doing this.

I am assuming I will need to torch all the bolts in order to break them loose, am I better off just cutting them off?

How do I gain access to the bolts between the downpipe and the cat? Would I be better off disconnecting the cat from the turbo to slide it all down?

Any tips appreciated.

Thanks

Tanzimur
04-08-2013, 07:04 PM
Basically remove the airbox and all from the left side gives you a ton more space to work with, and then you would unbolt the cat from the exhaust side of the turbo three bolts, two up top and one at the bottom which you will need a swivel socket for and then the rest is from underneath the car to release the down pipe with the cat!!!

ISHOT
04-08-2013, 07:09 PM
You will want to remove the cat at the same time, its damn near impossible to get the downpipe out by itself. The bolts were suprisingly easy for me to remove, but a torch is your best friend if you run into problems, i dont even use penetrating lubricant anymore. Just direct the heat on the nut and not the threads. Dont forget to disconnect the O2's!

Nevalite
04-08-2013, 07:58 PM
Thanks for the tips!

98A4TurboAWD
04-09-2013, 07:05 AM
Listen to me friend because this will save you a ton of time.

Do not waste the time trying to remove those bolts. If they are anything like mine they are round and seized. Even if you could get them out, which mine were impossible, you will not be able to separate the cat from the pipe. I had to beat mine with a chisel and hammer to get it to come apart.

My advice is to start by cutting the pipe under the car and then simply remove the 3 bolts on the back of the turbo and pull it out.

I literally wasted hours on a hopeless endeavor.

As you can see, each bolt had no shape that a socket could grip, especially being where it was on the vehicle. Further, it was clear that it had "welded" itself and was never going to come off.
http://i87.photobucket.com/albums/k126/carlosg815/20130207_213234_zpsbb2d8700.jpg

Once I got it off I had to chop the heads off each bolt.
http://i87.photobucket.com/albums/k126/carlosg815/20130207_213226_zpseaa13caf.jpg

It took a lot of hammering to break it apart even with the bolts out.
http://i87.photobucket.com/albums/k126/carlosg815/20130207_213737_zps83b879af.jpg

I suggest you do not even waste time trying to remove those bolts. I'm in MI and my car had 156k on it. Being in montreal, if your car has seen snow and salt then I would imagine yours is no different.

I replaced the flex pipe with this. It has worked great and cost me like $8.
http://i87.photobucket.com/albums/k126/carlosg815/20130208_133543_zps50ff8fbb.jpg

Nevalite
04-09-2013, 08:52 AM
Thanks for the advice and pictures. I fear that because of our salty roads I will face the same situation as you. I will take a look at the bolts and then decide what to do.

Thanks again.

bw86
04-09-2013, 09:24 AM
I didn't have a problem removing those 3 nuts. A twist socket would have most likely taken those nuts off

98A4TurboAWD
04-09-2013, 01:24 PM
I didn't have a problem removing those 3 nuts. A twist socket would have most likely taken those nuts off

I used a swivel socket. You hold an interesting opinion for somebody who wasn't there with me lol.

The socket had nothing to grab. What you are seeing is the top half. The underside where the bolt heads were was totally rounded off. Perhaps if there was room I could have hammered on a smaller socket and got it out, but even still, given the amount of work it took to break the cat from the pipe, there was no way I could have done it with it on the car.

jvega21
04-09-2013, 01:29 PM
I replaced the flex pipe with this. It has worked great and cost me like $8.
http://i87.photobucket.com/albums/k126/carlosg815/20130208_133543_zps50ff8fbb.jpg

I like that pipe you used. How did you attach that to the cat/tp? did you just cut the flange off and clamp it?

bw86
04-09-2013, 02:16 PM
The socket had nothing to grab. What you are seeing is the top half. The underside where the bolt heads were was totally rounded off.

http://www.tec-spiral.com/cn/images/Twist_Socket_01.jpg

These will save a bunch of headaches.

jvega21
04-09-2013, 03:02 PM
^^I second this. Life savers

98A4TurboAWD
04-09-2013, 03:37 PM
I like that pipe you used. How did you attach that to the cat/tp? did you just cut the flange off and clamp it?

Yes.