RS4 DownPipe Removal help.

[brad65ford]

Well already broke on of the studs even after soaking them. I really need some advice for removing the front 02 sensors, looks as though I can not remove the top downpipe bolt because its in the way. Just looking around I've seen someone suggests going from the top which seems crazy to think thats possible or a special tool. Anyway any tips would help greatly, already thinking i will hopefully be able to remove the stud some how after the dp is off .. i hope.

[brad65ford]

Well already broke on of the studs even after soaking them. I really need some advice for removing the front 02 sensors, looks as though I can not remove the top downpipe bolt because its in the way. Just looking around I've seen someone suggests going from the top which seems crazy to think thats possible or a special tool. Anyway any tips would help greatly, already thinking i will hopefully be able to remove the stud some how after the dp is off .. i hope.

Note to self, this sucks LOL. Ok seriously i found a bent 7/8 box wrench for when i did my s4 dp it worked to remove the o2 sensor on the right side. All 2 bolts unscrewed and 1 broken on the right side now. now the left. Wow can't believe what a bitch this is.

[65vetteC6]

Its just a bitch, I broke a few studs too. I was able to reach all the bolts without O2 removal though. You could drop the sub frame some if you want to get a little more room, or drop the trans brace too, just support the trans.

[brad65ford]

Its just a bitch, I broke a few studs too. I was able to reach all the bolts without O2 removal though. You could drop the sub frame some if you want to get a little more room, or drop the trans brace too, just support the trans.

Thanks buddy, what did you do when you had the header out, can you remove the studs with out drilling?

[65vetteC6]

I had the motor out but hopefully you can drill them out.


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[brad65ford]

Got it and job is done, wow not the most fun i've had working on the car but at least its finished. Sounds better with the cats out! Mil spacers worked perfectly, so far no check engine light wonder how many miles i have to run to see if there is an issue. Thanks for the help guys.

[Gareth_oau]

to take mine out I used a special tool called a credit card

[brad65ford]

to take mine out I used a special tool called a credit card

[BenSti]

You need a universal joint socket. Not a universal joint + socket, but an integrated one.

[voidopolis]

So, I broke 2 studs doing the same process. I put about 200 gallons of PB Blaster trying to loosen them up and tried heating the bolts - but still snapped off the two bolts. I found a local shop that does custom exhaust and they charged me about $75 to fix the broken studs and remove all the bolts and put them all back on with anti-seize so I can do the rest of the work myself.

[EUROSWAGR]

The key is definitely putting heat on the studs with the RS4. I'd recommend something hot too, I used a MAP/OXY setup and it took me 10 minutes to change out all the studs. Prior to that I spent about 4 hours trying to remove them with propane and PB blaster.

[brad65ford]

Wasn't that big of a deal cut the remaining stud as close to the flange and drilled it out. Used a new bolt with lock washers and it's back up and running. Best thing to do is cut the heat shield off when doing piggies. Helps get to the bolts and 02 sensors. Also used a bent wrench for the 02 sensor which I used on my old s4 dp's.