Lou4130

So my 2001 Cherokee sport the muffler is shot and it has no tail pipe. So i decided to just put a new muffler/tailpipe. I got a direct fit muffler with the flange that bolts up to the CAT. the bolts seem fine but the nuts are so rotted that there is no way i can turn them. One i MAY be able to grab with a vice grip to get it off, but the other is practically a "rust ring" rather than a nut lol. I was hoping maybe there was a trick to getting these nuts off? Im pretty sure i could saws all between the muffler and the cat but i dont have one and am trying to think of another way. I already soaked them in Blaster PB penetrating oil. Thanks in advance!

IJM

Can you get in there with an angle grinder or even a Dremel and cut those bolts off? If all else fails, you could always cut the flange section out entirely and use a butt clamp instead.

Lou4130

I was thinking maybe the dremel could get in there. I have metal cutting wheels for mine so i may give that a try. Id rather not have to cut the flange off, but if all else fails it may be the final option. Thanks man!

lawsoncl

Cut the studs, knock the rest out of the flange and use new bolts.

Lou4130

Yea i just thought to maybe do that. I have new nuts n bolts on the new muffler so i figured maybe i can just cut/grind off the head of the bolt on the muffler side. Dunno why i didnt think of that in the first place lol thanks man! Gonna try that!

Glasply

Sawzall between cat/muffler flange cut studs, may have to knock bolt/nut ends out of flange, then replace with bolts and nuts (self locking crimped head not nyloc lock nuts (heat will melt nylon out).

Lou4130

yea i had mentioned the sawsall in my original post, but i dont have one so was trying to figure out other options without me spending money right at this moment. The new muffler has the bolts built in and i got stainless nuts for them as well. I am likley going to either grind the bolt heads from the muffler side and push the remander of the bolts out or, borrow a saws all and do exactly what you said. thanks man!

awg

you may be surprised what repeated applications of just a strong butane torch will do to rusted fasteners, I dont even think about anything like that without heat

probably quicker to just cut them in this case

repeated heat cycling and cooling with penetrating fluid expands and contracts the metal, physically breaking the rust seal

does not have to get red hot, but oxy does work best for exhaust nuts

work the fastener back and forth, once its started a few turns, an impact will usually do the rest

Ralph77

IIRC from replacing the exhaust on my '00 the studs are part of the muffler.
If so just cut 'em.
Get some new nuts from the hardware store. What I did.
I recommend not using a regular muffler clamp for the muffler/tailpipe end.
Get one those step band clamps.
Like this:


Just for illustration purposes. Probably not the right size.
I would have to look up in my files what I bought from my Napa.

Lou4130

You are correct. the studs are part of the muffler. I currently don't have anything to lift the car up and dont own a saws-all (yet) so cutting them is a bit difficult to manage, but i am thinking it may be the quickest option. The new muffler has the studs and i got stainless nuts for it. XJ stock exhaust is 2.25, and i actually did get lap join band clamps for the muffler to tailpipe connection. Its going to rain for the next 3 days so i am stuck for now lol But im trying to locate a friend with something to cut it cuz i mean why go crazy right? lol

Ralph77

Be a pain but thinking you could get a hacksaw blade in there.

Lou4130

Also another note while we are in the area... the heat shield above the muffler has come undone on one side and is rattling around. I figure when i have the muffler off i should fix this. is it as simple as removing the nuts and replacing the washers that hold it and putting the nut back on or is it more complicated? Seems simple but i know what is seems, isnt always what it is lol

Lou4130

that thought did cross my mind lol Its on the options list lol

Ralph77

Put up a brand new one all those years ago when I did the exhaust.
Studs are part of the Jeep IIRC.
Pretty sure I used those speed nut things there.

https://www.ebay.com/itm/122359603591

Again just for illustration purposes.
Want to say that the size is .250-20 but again would have to check my files to see if I could figure out what I bought and the size I used.

Lou4130

Perfect! thanks! Figured it would be good idea since the muffler would be off!