Exhaust - Exhaust Leak Help | Ford Escort Owners Association (FEOA)
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Exhaust Exhaust Leak Help

Discussion in '2nd Gen 1991-1996 1.9L SOHC' started by kuwacs, Apr 27, 2013.

  1. kuwacs

    kuwacs FEOA Member

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    The bolts on my exhaust broke. The connection between the cat and the flex pipe. It seems as though one bolt snapped, and the other is holding in place well.

    The problem is, I can't seem to get the broken bolt out for the life of me. Granted, there's nowhere I've been able to get the car up high enough to really get at it, but still. Tips?

    Also, what sorts of things will I need to re-do this connection. The rest of the pipe is in great shape, it just seems that the exhaust was redone using the old bolts. I figure I'm just going to probably drill out the old bolts, put in ones slightly smaller than whats in there with a nut on the other end. Is there as gasket for it as well?

    Thanks
  2. denisond3

    denisond3 Moderator Staff Member

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    Do you know anyone with an oxy-acetlyene torch that you can take the car to? You would drive it up on ramps, and the person would use the torch to get the stubborn bolt up to the color of a school bus - and then it would either come out with some hammering or turning with a box end wrench on it (By all means, use a 6 point wrench, not a twelve point). - or visegrips maybe, or sliced off using the cutting tip - if the operator of the torch knows his business. I have taken those bolts out on each of my Escorts. and I have had to use my oxy-acetylene torch on some of them.
    To get the old ones out you should spray with penetrating oil liberally. And it wont hurt to hammer the head of the rusted bolt - or the nut on its other end; using the hammer to whack them sideways. A cold chisel might be helpful. When re-installing new bolts, coat the threads liberraly with antiseize compound. Always use a new gasket too. I had one joint that was rusted enough that it still leaked with new gaskets. I put some of the orange colored Permatex RTV on it, and let it cure overnight. I took it for the annual safety inspection the next day and it passed. And more than a year later, it passed again & still isnt leaking.
    I like to replace those original bolts with new ones made of stainless steel - with mild steel nuts. I would avoid using stainless bolts AND stainless nuts, as they may eventually 'fuse' together.
    With all of the ones I worked on, you need to have nuts on the end of the bolts - there isnt any threaded region on the two mating flanges. I think I used m10 bolts, but Im not sure.
    Another trick to make it -easy- to get the bolts out next time, is to put an extra nut or two onto the end of the bolt, in addition to the first nut. I prefer brass nuts, though they can be hard to find in metric sizes, or acorn nuts (cap nuts). The idea is that I have covered the threads entirely - and swabbed them with antisieze compound during assembly. Exposed threads will corrode, but threads covered by extra nuts stay nice and workable.
  3. Intuit

    Intuit FEOA Member

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    If space is an issue, removing the radiator (or exhaust manifold) should help. If equipped with A/C, the condenser will still be in the way though.
  4. kuwacs

    kuwacs FEOA Member

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    Just thought I'd let you guys know. I decided to wing it!

    I used a saws-all to cut the not-broken bolt. The other one came out along with what was left of the flange. Used gasket material to cut a new one, and a set of bolts, crush washers and nuts to clamp it back together.

    Turns out it has been leaking since I got the car, cause I was really happy once I got it back on the road :)

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