Muffle Query and Rusty Bolt Removal

[johnhh]

Hey guys. I searched first to see if I could find any threads with tips on removal of severely rusty bolts to no avail, so I snapped some pictures, and am coming to you for help/ideas.

Some everyday information first: 1998 T4R SR5 3.4L - 225k miles.

The bolts at the union between the Cat and the Muffler are in pretty bad shape. Here are some snaps of them to get a better idea:

Any ideas what the best way to get them out. I am looking to replace the muffler but leave the Cat and Tailpipe in, so I've got quite the job ahead of me I know. I've tried wire brushing, soaking in some namebrand rust removal, using a mini wire brush on a Dremel, and even went at it with a chisel. It's pretty solid stuff.

On another note, I'm wondering if anyone can tell me what this item attached to the pipe just before my muffler is.

What is it? I don't see it in in the pictures of the Muffler I've been considering for purchase: BOSAL Rear Muffler from Car-stuff.com.

Lastly, I was wondering if, considering the job I am about to start, if anyone could point me in the right direction for the gasket and bolts I am going to need to replace. Would it just be the most convienent to buy them from the local dealer since the parts are so inexpensive, or should I look for an online/local alternative?

Thanks for the help,
Hank (johnhh's son)

 

[wolfgang]

I used a 3" cutoff wheel on an air powered grinder. Cheap from Harbor Freight if you have air compressor. Could use an electric grinder if you can fit it in. Other alternatives are chistle and hammer or a hack saw. Of course assoumming you don't have a plazma cutter or cutting torch. The hanging piece is to cancel vibration - I know it looks strange and add on. I am on 3rd or 4th Bosal system on my '90 4Runner. They came with a lifetime warranty (from Olympic Autoparts). THey are good for 40k miles.

 

[bxc13]

With rusted bolts, I've always tried to removing with PB blaster, 6 point sockets (12pts will strip) and a propane torch. However, yours looks pretty bad and you will likely have to cut it with a dremel and drill out the old bolt (as previously mentioned).

Good luck,
Bill

 

[johnhh]

Thanks for the advise. Time for some grinding...