rustywaggy

Hello. I have a 88 Wagoneer 4.0 that I am trying to put new exhaust on. I have a new headpipe, cat, and cat-back system but I am at a standstill here. I have removed one of the two nuts from the exhaust header but have rounded the hex off of the other one. My header surprisingly does not have any cracks so I am looking to save it.


Is there ant way I can remove the nut without damaging the stud? I had thought of cutting it on both sides with a dremel tool but that might take a while. I am drawing blank on any other ideas. I have fixed a mile long list of other things it needed but this has me at a standstill. Thanks in advance for any information.

KJamesJR

You can cut into them with a dremel tool. It doesn't take too long, though you'll burn through probably 4 blades. You'll also end up cutting into the threaded rod a bit. However this shouldn't be a huge issue. After to make the two cuts on either side... Tap it with a hammer, or in my case, the end of your box wrench.

You can also try replacing the stud when you're finished, though I don't know how you would get it out of the block...

OR

You can file the head back to an original hex shape, PB it, and try again. It will take longer, and you'll need a smaller box wrench. Though it won't damage your threaded rod... Unless you snap it.

rustywaggy

This is the studs that hold the downpipe to the manifold. I will try the dremel idea but there isnt a whole lotta room up there and I am laying on my back the whole time. If I can get the nut off I can clean up the threads with a die (i hope). Thanks.

salad

Those are studs on the Renix XJs? On my 99 they were just bolts, hacked up the old manifold with a sawzall to get enough room to cut the bolts

5-90

A Dremel with a small cut-off wheel will work - just watch your depth.

When you get replacements, use 3/8"-16 brass nuts. Trust me - they won't seize up like the steel ones do, and they're just fine with the low torque.

(How do I know they work? Been using them for years myself...)