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Stripped Exhaust Bolt. How to remove?

Discussion in '2.5 Gen Tundras (2014-2021)' started by SoCal_Tundra21, Mar 2, 2025.

  1. Mar 2, 2025 at 5:37 PM
    #1
    SoCal_Tundra21

    SoCal_Tundra21 [OP] New Member

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    I was in the process of removing my muffler and the top bolt between the muffler and cat stripped. It won't go back in and it won't go out anymore than in the picture.

    How would I remove it now?

    PXL_20250303_010802036.jpg PXL_20250303_011054733.jpg
     
  2. Mar 2, 2025 at 5:44 PM
    #2
    TILLY

    TILLY Gently Used Member

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    Sawzall with a fine metal blade for the win.
     
  3. Mar 2, 2025 at 5:45 PM
    #3
    ZappBrannigan

    ZappBrannigan The mind is willing but the flesh is weak

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    Heat and vice grips or just cut it off if there’s access.

    sometimes a nut cracker will work if there’s clearance

    heat, generally on exhaust parts before trying to remove them is helpful.
     
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  4. Mar 2, 2025 at 5:45 PM
    #4
    BeauDacious

    BeauDacious 040 > all other colors

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    One thing you can try.

    Remove the lower bolt. As you spin the upper bolt to remove it, gently pry the flanges apart to help pull the bolt out of the nut.

    If your lucky this will work and you'll have stripped the bolt and not the welded on nut.
     
    1lowlife and SoCal_Tundra21[OP] like this.
  5. Mar 2, 2025 at 5:46 PM
    #5
    ZappBrannigan

    ZappBrannigan The mind is willing but the flesh is weak

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    I bet he’s more likely to lunch the mating surface and cause himself more problems.
     
  6. Mar 2, 2025 at 5:49 PM
    #6
    F.I.LetGoFishing

    F.I.LetGoFishing New Member

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    Stripped as in spins free or froze in place or is the nut rounded out?
     
  7. Mar 2, 2025 at 5:49 PM
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    BeauDacious

    BeauDacious 040 > all other colors

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    Plenty of room above the bolt / nut to put a prybar between the top of the flange. I was not suggesting he grunt on the thing, just apply a bit of force to get by the hopefully stripped thread into a good one to make it move.
     
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  8. Mar 2, 2025 at 5:52 PM
    #8
    Tundra family

    Tundra family New Member

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    Run the truck for a few minutes, let that pipe get good and hot.
     
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  9. Mar 2, 2025 at 5:54 PM
    #9
    TacomaTRD4x402

    TacomaTRD4x402 New Member

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    I'd start with lock pliers on the nut n hit the bolt with an impact. If that don't work, sawzall like @TILLY said.
     
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  10. Mar 2, 2025 at 6:16 PM
    #10
    SoCal_Tundra21

    SoCal_Tundra21 [OP] New Member

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    Thanks for the suggestions everyone
     
  11. Mar 2, 2025 at 6:35 PM
    #11
    SoCal_Tundra21

    SoCal_Tundra21 [OP] New Member

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    The threading is stripped on the bolt or nut.
     
  12. Mar 3, 2025 at 4:20 AM
    #12
    F.I.LetGoFishing

    F.I.LetGoFishing New Member

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    Nut splitter or saw.
    If they did these like my fist gen taco, you may need to get replacements from dealer as the nut is specialized(takes different size wrench) to fit down inside the flange.
     
  13. Mar 3, 2025 at 7:59 AM
    #13
    Coastboater

    Coastboater New Member

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    Cut the bolt head off after putting vice grips on the nut so it can’t spin, otherwise the bolt will spin making the cutting much longer.
    Snap-On, Snap-Off:D

    edit to add - if you can’t get a Sawzall in there, a pneumatic 90 degree die grinder with a cut off wheel on it would make quick work. If you use that, you have to keep the bolt from spinning- vice grips on the nut.
     
    Last edited: Mar 3, 2025
    ZappBrannigan likes this.

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