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Old 03-09-2010, 11:41 AM   #1
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Exclamation Need Help - Up a Creek, Need an Oar.

Crap! OK I'm changing my CAT as it's shot, and I broke both the flange studs that connect the manifold to the down pipe. Both are broken, I don't think I can drill them out to just put bolts in, at least not without it being a multi-hour project and possibly damaging the flange. What can I do? Do I have any other options? Is there a way to get them out that I can't see because there's so much rust on them? Any help appreciated.

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Old 03-09-2010, 11:42 AM   #2
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Any other way to connect the pipe other than welding?

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Old 03-09-2010, 12:04 PM   #3
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I believe there is some kind of C-clamp type bolt set up for just such a problem. Atleast that's what a mechanic told me several years ago when my old truck had the same problem.
Sorry I don't know a specific part name, but I do believe this wont be too much of a problem, once said clamp/bolt is found.

I tried an image search, but didn't find it. Maybe someone else knows better.

EDIT:
HERE is what I'm referring to, from JC Whitney.
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Old 03-09-2010, 12:07 PM   #4
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I believe there is some kind of C-clamp type bolt set up for just such a problem. Atleast that's what a mechanic told me several years ago when my old truck had the same problem.
Sorry I don't know a specific part name, but I do believe this wont be too much of a problem, once said clamp/bolt is found.

I tried an image search, but didn't find it. Maybe someone else knows better.
That's what I'm hoping for... :fingerscrossed:
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Old 03-09-2010, 01:05 PM   #5
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Sorry to jack your thread but I will be doing the same in the next few weeks since my cat is fried (at least according to the CEL I'm throwing). I'm just curious to if you are replacing just the 2 front precats or if you are doing the rear as well. Also curious to where you ordered the new ones from.

Thanks again...good luck!
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Old 03-09-2010, 01:08 PM   #6
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Precats??? Mine's only got one main rear cat - just prior to the muffler and above the TC skid. This is what I'm using - MAGNAFLOW CATALYTIC CONVERTER 97 99 JEEP WRANGLER 23227 : eBay Motors (item 280472145395 end time Mar-31-10 02:50:52 PDT)

The cat was definately shot.... I found part of the cat in the muffler, LOL.
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Old 03-09-2010, 01:12 PM   #7
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Ah...yeah I think its because I have a 2001 and its a dif design. I have 2 "pre-cats" that come off the exhaust mani right before the O2 sensors and then a big rear cat somewhere underneath. I have heard many dif arguements on which ones I need to replace to get rid of the code but from the sounds of it I need to do the 2 off the exhaust mani 1st since those are right before the sensor. Of course it would have to be the more expensive of the two. The cheapest I have seen so far are about $350 then another $150ish for the rear if needed.
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Old 03-09-2010, 01:19 PM   #8
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For the little $$$ it should cost to have a small independent muffler shop (NOT like a chain muffler store like Midas!), I would just let them do it. It would only take them a few minutes to cut/weld/whatever is needed. I did that when I had to replace install a cat I puchased online & they only charged me $15-20. You know the type of shop, old & locally owned with piles of old rusty exhaust systems laying around and the Harley-riding welder missing a couple teeth.
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Old 03-09-2010, 01:28 PM   #9
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Originally Posted by Jerry Bransford View Post
For the little $$$ it should cost to have a small independent muffler shop (NOT like a chain muffler store like Midas!), I would just let them do it. It would only take them a few minutes to cut/weld/whatever is needed. I did that when I had to replace install a cat I puchased online & they only charged me $15-20. You know the type of shop, old & locally owned with piles of old rusty exhaust systems laying around and the Harley-riding welder missing a couple teeth.
I'm with Jerry on this one...esp given the broken bolt issue.

I'm all for DIY. but when stuff starts to break...its often cost worthy to let them do it.
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Old 03-09-2010, 02:11 PM   #10
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Originally Posted by Jerry Bransford View Post
For the little $$$ it should cost to have a small independent muffler shop (NOT like a chain muffler store like Midas!), I would just let them do it. It would only take them a few minutes to cut/weld/whatever is needed. I did that when I had to replace install a cat I puchased online & they only charged me $15-20. You know the type of shop, old & locally owned with piles of old rusty exhaust systems laying around and the Harley-riding welder missing a couple teeth.
Yeah, plus the cost of a tow.

I'm going to take a break and go get a new bit for my mini die grinder so I can get on top of that flange cleanly.

Damnit!!!
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Old 03-09-2010, 09:25 PM   #11
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Originally Posted by Jerry Bransford View Post
For the little $$$ it should cost to have a small independent muffler shop (NOT like a chain muffler store like Midas!), I would just let them do it. It would only take them a few minutes to cut/weld/whatever is needed. I did that when I had to replace install a cat I puchased online & they only charged me $15-20. You know the type of shop, old & locally owned with piles of old rusty exhaust systems laying around and the Harley-riding welder missing a couple teeth.
I ended up letting the frustration get the best of me. I wish I had a lift. When things go wrong it ends up being trip after trip to the tool box and then crawling back under the Jeep on the concrete... ...you guys all know the routine. Anywho Jerry, still a little chilly here for Harley's, but I took your advice and ended up taking it to a 2 stall automotive shop that sells fishing tackle out of the office.
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Old 03-10-2010, 05:40 AM   #12
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if you have a wrangler pre 03' just take it out. (pre 03's didnt have o2 sensors after or before the cat under the skid only at the pre cats) mine was fried, didnt wanna dish out the money for a new one so just went to auto zone bought a piece of 2 1/2 straight exhaust pipe used 2 band clamps and thats it. and also put a super 40 flowmaster in with 2 1/2" pipe all the way to the tip.

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