Removal of stock exhaust

[4RunnerRon]

Has anyone figured out how to remove the stock exhaust system WITHOUT cutting the rear pipe/resonator to get it out? I'm trying to break loose the two flange bolts behind the muffler, but the nuts facing the ground are spot welded from the factory and the top of the bolts won't budge. Space is limited for reaching them, but I've tried WD-40 and lots of muscle, all with no results.

I'd like to retain the stock exhaust when I replace it, so if I can avoid hacking that rear piece with a sawzall, that would be great. Any help from you guys who have done this already would be appreciated. I have the Borla out of the box and ready to go!

 

[truckhigh]

iknow how you feel. I ended up loosening 1 with a 3/8 socket and a 4ft pipe. the other one i ended up using a sawzill to cut he nut that is welded to the flange. now if I want to put my stock exhaust back on I just have to uise another bolt and nut. The design of the rear section is horible. You are not able ot get to it with a decent sized wrench. PLus not even seeing if the bolt is stripping.

 

[4RunnerRon]

Wow, I'm surprised you were even able to get a 4 foot pipe under there for leverage on that one bolt. I've tried a small breaker bar, but it doesn't budge at all. Even getting a sawzall in that tight space to cut the welded nut sounds impossible.

 

[Spider5]

Use a close quarter air wrench it took about 15 seconds for both bolts.

 

[Casper]

hmmm, interesting...i really had no issues loosening the nuts and bolts on mine.

 

[X6RUNNER]

....Ron, I've forgotten the exact size of those bolts. But if my brain serves me right then they are 12mm (Metric). Remember, I've helped a neighbor to temporary fix his broken muffler on his 05 Sport just few days before New year. Yes, those bolts are very tight. specially, his car is one year old. I do have air compressor with a mini impact wrench, but it didn't work. Here what I used. Spay lot of WD-40 over the nuts and bolts. Use one ratchet wrench serves as primary, and a regular box wrench serves as extention bar. Place the ratchet wrench onto the bolt that need to be removed, swing the primary to the best openning position, then connect the box wrench to the open end of the primary wrench in the interlock position. Hold your breath and snap it. It worked for me so goodluck. Look at the pics below. BTW, i'm still waiting for your PM since Jan/19.

 

[X6RUNNER]

...To more pics.

 

[X6RUNNER]

...Last one. This is non-reversible ratchet wrench. The Reversible wrench is more helpful.

 

[4RunnerRon]

Hey X6RUNNER! Thanks for the help, and especially taking the time to post pics.

As for not getting back to you with a PM about the HIDs, my computer was in the shop for a week and a half. Just got it back and uploaded the install pics. Check out my writeup under the Accessories forum for install instructions and my review of the XenonDepot HID kit!

-Ron

 

[cashflow50]

i believe the flange bolts are 14mm

 

[revox92]

i believe the flange bolts are 14mm

All I know it's 14mm. We've just installed a new muffler on buddy's 4Runner, headache rack and tonneau cover on his truck.