Catalytic Converter Removal

I bought new cats and O2 sensors for mine recently and had the same problem as you. I was able to get the front bolts out but the ones toward the rear are rusted and rounded. You can try to get a nut extractor that is the right size or just cut them with a sawzall. You can replace with nuts and bolts, just get something zinc coated or other rust resistant metal and coat them with some anti-seize so future you doesn't have to go through the same painful experience.

Good luck

One of my favorite tools is a Bult Buster. It heats up any metal bolt, nut, etc., through magnetic induction. Heats up bolts and nuts like a torch but without the flame. For something like this, I would use the Bolt Buster to get the bolt or nut cherry red hot and use an extractor. Or, if it's too late for an extractor, get it molten hot and take a chisel to it. A Sawzall or oxy-acetylene torches are other options, but it depends on the room you have and what is around it. If it's studs, you may end up having to cut them and then drill/tap a new threaded hole and replace the stud (or use a bolt).

Jpferris127 said:

So I'm trying to remove the exaust but the bolts on the one catalytic converter the bolts are rounded out and can't get them off. What are some tricks to get the bolts off without damaging the converter. Also can you buy new bolts to replace the bad ones or do you need to buy a whole new converter. Thanks for the help.

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If you're replacing the cats, just cut them off. New cats will not have studs, like the OEM cats do. If you're reinstalling the OEM cats, cutting them off will force you to drill the studs out. After this many years there's little chance of getting them out without cutting and drilling. I spent way too many hours trying to get the OEM nuts off, finally I just cut them off with a cutoff wheel, then once the cats were out I drilled out the studs. It was so much quicker doing it that way.

If you're replacing the OEM cats, just cut them off. The new cats will come with new bolts and nuts, no need to drill out anything.

The stripped nut extractors didn't work for me. The original hardware was just too seized up to remove.