Exhaust 300tdi removal

BostonTar · Nov 26, 2021

Trying to remove my old exhaust and replace but having issues getting this nuts offs. Can I cut them? As I can’t see how they will fall out. They look attached to turbo? Or do they have to be left for new exhaust pip to slot onto?
Photo attached, thanks.

Kev12 · Nov 26, 2021

Its much easier if you can leave the studs undamaged as any you cut or break off will need to be replaced. A nut splitter could be useful although I'd probably get them hot and use a really good fitting socket.

BostonTar · Nov 26, 2021

Kev12 said:
Its much easier if you can leave the studs undamaged as any you cut or break off will need to be replaced. A nut splitter could be useful although I'd probably get them hot and use a really good fitting socket.

Managed to get two off. The third one at the back is rounded and beyond repair. Could I just drill it out and spot weld a new thread in?

neilly · Nov 26, 2021

BostonTar said:
Managed to get two off. The third one at the back is rounded and beyond repair. Could I just drill it out and spot weld a new thread in?

Have you tried hammering home an irwin nut remover? if you can clear the thread, or even a long series smaller socket to get a bite?

Cheers

kevstar · Nov 26, 2021

That will need heat to remove it, heat the flange round the stud that the rounded nut is on then
heat the nut & hammer a smaller socket onto it or irwin, better with an impact socket a normal one may
split. If you cut it off you can use a stud extractor to get the rest of the stud out. If youve got no
heat run the engine for while & hammer the socket on the stud, it may shift.

BostonTar · Nov 26, 2021

Purchased a nut splitter but I’ll try the heat gun first. I’ll update here when solved! Cheers all!

Ratae · Nov 27, 2021

I find a Dremel (or similar) with the flexible extension & the small reinforced cutting discs very useful for cutting things - incl nuts - in tight spaces.

BostonTar · Nov 29, 2021

Update: No luck had to cut it! The nut cracker didn’t fit behind the stud. Probably the original nut since 1996! Thanks for the help however, useful tips!

v8250 · Nov 29, 2021

Soak nuts/threads with Plus Gas for a couple of days. Then apply heat using MapGas [butane's not hot enough] then crack off. They can be buggers to remove and the stud will often come free with the nut. Although a tight space it is possible to get a bar onto the socket head, it only needs the first crack to release, then back to ratchet and long socket. Buy all new nuts, washers and studs to do a proper job applying liberal amount of ceramic grease/copperslip upon reassembly.

Exhaust 300tdi removal

BostonTar

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Kev12

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BostonTar

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neilly

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kevstar

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BostonTar

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Ratae

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BostonTar

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v8250

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