Hi guys,

While removing the main mid muffler/silencer, the studs on the front flange (flange with the 2 bolts without gasket) sheared off. Does anyone know how the studs are fitted into the flange? Are they threaded or welded in place?

I want to remove the studs and replace with bolts but want to know the best way of removing the old studs. I am hoping that I can get around drilling them out , especially since it seems the flange cannot be removed from the y pipe to do it...

Any suggestions?

Thanks for your help.

Kevin B
2004 DII

 

Mine were welded in. I spent some quality time under the truck drilling them out. Pain in the ***.

You could always drop the entire Y pipe but that also can be a pain.

 

got a buddy with a torch? Save a ton of time. cut out old studs and use through bolts?

 

Thanks for the replies guys. Do you think I might be able to simply grind the head off the stud and knock it through? Or will drilling be a must?

 

They are studs, and they are in there good.
Takes Alot of effort to get them out, and they are hardened and like to eat drill bits.
Use fire.
I swapped mine for bolts, and it was a pain.

 

Depending on the condition of your flange, I found it easier to cut the flange off and install a split flange purchased off amazon. My bolts were a mess since I live in Chicago.

 

+1
I also ended up cutting off the old one and replacing the clamp over the flange.
Much quicker and easier.

 

Split flange? This sounds like a great option. I saw a post recently where someone said the holes didn’t align with the split flange. Can anyone provide a link for a flange that worked for them?

 

I drilled the stud heads off and used a mallet to whack the threaded side until they popped out. Would be easier to drop the Y pipe as any whacking could mess up the manifold to Y studs/ gaskets. I then replaced the studs with some zinc bolts and nuts so I didn't have to worry about rust again. My only issue was that I over tightened the new bolts and had to back them off a little bit.

 

Here you go on the split flange. It works!!2.5" 2-1/2" inch Exhaust Flange...