So Fix it

A rusted bolt is the result of iron or steel which has been exposed to water and air and has oxidized. When a bolt cannot be removed by using standard hand tools, the entire bolt is probably rusted. Heating a bolt will sometimes loosen it, but if heat is not an option for safety reasons, then impact or pneumatic tools may be the best and easiest way to remove the stubborn bolt.

Impact Wrench and Socket

An impact wrench can be manually operated or powered by electricity or compressed air. When powered by compressed air, the impact wrench is called a pneumatic wrench. To use a manual impact wrench, place the impact socket over the head of the rusted bolt. Hit the other end of the wrench with a hammer while holding down the wrench. The wrench is designed to transform the downward force into a turning motion which will slowly loosen the bolt. Spraying the rusted bolt with penetrating oil and letting it sit for 24 hours may help the process. Electrical or air-powered impact wrenches work the same way but use a trigger to supply the rotary motion. If the threads of the bolt are very rusted, the force of the electrical or air-powered impact wrench may break off the head of the bolt.

Pneumatic Cut-Off Tool

A pneumatic cut-off tool can be used to cut through a small-to-medium size rusted nut or cut off the head of the bolt. The pneumatic cut-off tool is air-powered and has an abrasive disk that rotates at a speed of up to 20,000 rpm. Be sure to wear gloves and safety glasses, as the cut-off tool will create a shower of sparks.

Pneumatic Hammer

A pneumatic hammer and a cold chisel attachment will shear off large bolt heads and nuts. A pneumatic hammer is an air-powered device with a metal piston that mimics the movement of a hammer. The chisel attachment will quickly pound off the head of the bolt or break the rusted nut. Be sure to wear gloves and safety glasses.

Pneumatic Needle Scaler

A pneumatic needle scaler or needle gun can be used to remove rust from around the bolt. A pneumatic needle scaler is an air-powered, hand-held tool that uses little chisels or needles spinning at high speed to remove paint and rust from hard metal. You can use a needle scaler in conjunction with penetrating oil and the impact wrench and socket.

Rust is a problem no matter where you find it. But when its the bolts and nuts on your exhaust system, it can be a little bit trying. There are multiple ways to remove a rusted bolt from the exhaust, and it will take time and patience to do it correctly.

Instructions

1

Lift up the vehicle using the jack, and support the vehicle on jack stands. Make sure the vehicle is secure on the stands before you crawl underneath it.

2

Apply the penetrating oil on the rusted nut and bolt. You want the oil to soak the area where the bolt and nut connect on the exhaust, because thats whats holding things together.

3

Attempt to loosen the nut from the bolt using the 3/8-inch ratchet and sockets. If it doesnt come off right away, try using the 3/8-inch breaker bar to add extra leverage.

4

Place a fire extinguisher under the vehicle in preparation for the next step. Put on the welding gloves on as well.

5

Heat the bolt on the exhaust system using the Mapp gas torch. The penetrating oil may burn a bit, but it shouldnt cause a fire. Heat the bolt until its red.

6

Try to remove the nut or bolt using the 3/8-inch ratchet and breaker bar. This should free the bolt from the nut, but if not, proceed to the next step.

7

Attach the angle grinder to the air compressor using the air hose, and cut off the nut and bolt. This is a last-ditch effort, but it will remove the hardware from the exhaust. Then you can replace it with new hardware.

Broken exhaust flange bolts can be a source of major frustration in any auto repair project. The bolts usually break because of rust and corrosion from the intense heat and high moisture produced by the exhaust. A few options are available if the bolt is broken off above the surface of the exhaust component. However, most of the time the bolt must be drilled out before it can be extracted. Extreme care must be taken to avoid damaging the threads, rendering the component useless.

Instructions

1

Spray a liberal amount of penetrating oil on the broken bolt. Lightly tap the bolt from each side to allow the oil to seep in. Spray the bolt again and let sit for 24 hours if possible. Spray the bolt once or twice during the wait.

2

Clench the bolt in a pair of locking pliers if there is enough sticking out above the surface to grip. Try applying pressure to see if the penetrating oil loosened it enough to remove normally. Be careful not to break the bolt further.

3

Put on the safety goggles. Using the grinder, grind the bolt until it is flush with the surface, then use the punch and hammer to mark the drill guide in the exact center of the bolt.

4

Insert a small left-handed drill bit (less than 1/8 inch) into the drill as far down as it will go. This increases the control you have over the bit. Place the drill into the punch hole and begin drilling slowly while adding pressure. Reverse the drill and clean out the shavings every so often.

5

Increase the size of the bits gradually to increase the hole diameter after each successful pass. Repeat this process until only the threads of the bolt remain. Pull out the remaining pieces or pass a tap through the hole to collapse them inward.