Well that 40fpt really got me screwed! I had a few hours to spare this afternoon, and for the life of me...... I COULD NOT BREAK ANY OF THE 4 DP BOLTS! I tried extra leverage, no go, I tried small ball-peen hammer, nada. I even busted a knuckle in the process. nothing. God damn rusted studs! Cuz I know I didn't tighten it over 40, and the odds of cross-threading 4 stems is unlikely. I even put on the welding gloves, and tried while hot, and it was hot, still nothing.... Scratching my head here.

Here is the problem. I don't want to apply a solvent, in case I still can't get it off; the solvent will make for one hell of a fire starter! Heating bolts and fittings has always worked in the past, I'm at a loss here, again I'm not looking to BBQ.

If no options exist... I'd really feel schmucky having the shop down the street crack 'em for me. I mean it's 7 bolts and an O2. Pisses me off!

It has been a few years, does anyone know how flamable navel jelly is?

Damit! I've been running with the stock DP - gutted for a long time, and now stymied by some rust, and crappy weather! +1 for HAHN btw, ordered and shipped within a week. Looks like they are settled in Florida. The welds are stop and turn, not continous, but heated through, and colored nicely. I wish I could say more. ****in Rust!

EDIT:
I think I just answered my own problem... Carry my but down to Harbor Freight and and make that long overdue impact wrench purchase.

 

no naval jelly or solvents needed or worthwhile. Get some good penetrating lube of your choice and let it soak. Bu honestly nothing beats heat, either get a torch and make the nuts nice and red or run the truck under heavy load to get them hot as possible.

 

i had the same problem in tightening the bolts back on the dp to exhaust flange when putting my stock dp back on...they would not tighten down...totally felt cross threaded but weren't. gm uses one time use flywheel bolts...did they do the same thing here lol

 

I've had my DP off about 15 times for different reasons. I use an Ingersol High end Composit impact 1/2". Another trick is to get the nuts hot with a torch. At that time spray penetrating oil on the nuts. It will smoke, not catch fire. The oil cools the nuts and at the same time is pulled into the threads. Do this several times and you should be able to use a 1/2" rathchet with a long handle or breaker bar. Long handle is key to getting stuck bolts off.

 

..or get hot and use candle wax....wax wicks right up the threads and creates a lube...and smells good if you use scented.....

 

IMPACT guns do the trick.

 

I am gonna go the Impact route, although I'm digging the wax idea.

Thanks all

 

Let's see. Red hot nuts, candle wax, and lube? I must have clicked on the wrong link...

 

Spend some weeks at the gym.

 

sometimes just whacking the bolt with a hammer will loosen the rust enough.