I needed new cats on my 2002 disco so I got a bolt on y assembly. I am having trouble getting the pipes to seat and connect properly at the exhaust manifold. Did I read somewhere in these forums that people change from using those pins to a bolt or a bolt and nut? Can some one fill me in on this? Or, what is the trick to getting the pins to work properly? I did get a kit with new gaskets and new pins and new nuts.

 

When you say "pins" are you taking about the exhaust studs like this> Land Rover Exhaust Manifold Stud Kit | Land Rover Exhaust System Parts


What brand cat did you buy?

 

Yes the studs. It was exactly that kit that I got. Cant remember the brand of cats. I could look it up but I don't have it with me. I have acctually driven it now even with the leaking exhaust and it's performance is so much better. Confirms that mine were clogged.

 

When you installed it, did you get the cat to mount to the 6 studs/manifold with the gaskets flush/flat BEFORE connecting the muffler?

 

Yes though I didn't start it up to confirm no leaks at that point so Im not sure it was perfectly flush. All 6 nuts were tight though before I attached to muffler.

 

I ask that because I've seen people connect the 2 bolts at the muffler(even loose) and it pulls the cat just off the manifold. Then when you torque it down that way the gasket never seals.


Have another look at it. And as for the brand, if it's something like BOSAL all bets are off that even the tops of the flanges are true.


You probably already know this, but be careful removing the nuts at the exhaust studs... THEY BREAK VERY EASY. And you asked about using a bolt. It's a M8x1.25 with a metal lock nut (like in the kit). You can use a bolt, but they can be difficult to reach to get the nut in place. Don't try a bolt or even crank down on the nuts you have on now to make up for a bad flange. Again take another look at your parts/install.

 

If the flanges are true and there are no other forces pulling or holding the pipes away from connecting flush, should the Nuts just pull the flanges up and tighten up? Or is there some trick to using the studs? Like do they need to be in all the way before connecting the pipes, or will they pull in as the nuts are tightened?

 

" Like do they need to be in all the way before connecting the pipes, or will they pull in as the nuts are tightened? " and there is the problem. The studs are not tight in the manifold flange.


How did you install the stud into the manifold flange?? You need to use 2 nuts on the stud, and then tighten the stud. Google for a better video. This is a BS vid, but this is the idea... start watching at about 3:15

 

Thanks OverRover. I pulled it all off and installed the studs correctly. It went together nice and now I am noise free and have power like a regular car. I can get up to highway speeds at the same rate as other cars. What a nice thing! Thanks again for your help. Now that I have worked with the studs, I can see how the design works.