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how to remove exhaust flange bolts

Discussion in '1st Gen Tundras (2000-2006)' started by xaq, Aug 13, 2025.

  1. Aug 13, 2025 at 7:05 PM
    #1
    xaq

    xaq [OP] 2003 4WD AC SR5 TRD Off-Road

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    What do I have to do to these? I got the other side's flange off with a dremel and rotary hammer chisel, but now the chisel is dull and it's been a PITA to remove the bolts on this side. Additionally, i cut off one bolt but not low enough, and have destroyed all hope of getting a socket on due to the hammer drill :/ impact worked for 1/6.

    2025-08-13-18-48-41-331.jpg
    2025-08-13-18-48-37-182.jpg
     
  2. Aug 13, 2025 at 7:10 PM
    #2
    Sirfive

    Sirfive Socially feral

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    Prayers and penetrating oil? Some heat would probably help, but i’ve got a feeling the studs might break.
     
  3. Aug 13, 2025 at 7:20 PM
    #3
    xaq

    xaq [OP] 2003 4WD AC SR5 TRD Off-Road

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    Penetrating oil and an impact didnt work. Ran the impact until the socket didnt fit. Rotary hammer got one turning, but nothing left to grab on the one I cut off and cant reach the deep one with the rotary hammer. Feel at a loss.
     
  4. Aug 13, 2025 at 7:25 PM
    #4
    Jack McCarthy

    Jack McCarthy Happy hour; beer goggles, not a fake profile.

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    Heavy duty bolt extractor?
     
  5. Aug 13, 2025 at 7:26 PM
    #5
    xaq

    xaq [OP] 2003 4WD AC SR5 TRD Off-Road

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    Definitely up there in my options, though i cant fit any of my drills in the area, so going to have to get some long bits.
     
  6. Aug 13, 2025 at 7:28 PM
    #6
    Jack McCarthy

    Jack McCarthy Happy hour; beer goggles, not a fake profile.

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    Heat would be my first goto. Preferably a torch.

    Heat the flange/nut around the bolt to expand the hole, hammer on the extractor and use an extension with a breaker bar to wiggle it back and forth until it breaks free for full rotation.
     
    Last edited: Aug 13, 2025

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