Dumpipe removal - SOLVED

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Dumpipe removal - SOLVED

Postby Tys91 on Sat, 15 Dec 2012 7:06 +0000

Well gday for you guys anyway! let me kick of this thread by saying f&^$& ^e d$$@# !!! Yep im bloody fustrated, ok guys ive been in the process of replacing my exhaust from turbo back. All was pretty straight forward. Everything come off like a dream. Thenas i got to the dump pipe trouble was calling me.Had trouble with the dump pipe bolts, thanks to hilux max who asissted me in removing the bolts as much as he could and gave me much advice ( thanks max) now im after anyone else who has ran into the same problem and found a way other than removing the turbo. I used a impact socket for great grip make sure the socket is single hex not double sided hex shape and a rachet with a breaker bar for leverage( worked a dream) i then went to remove the lower nut and booom! Its So hard to access from the top (engine bay) as i did with the top 2. I tried everything , jacked the car up removed the wheel and inner engine bay gaurd protectors to access the rear of the turbo still no go. Used the exact same method. Tried many others, no go. I even tried getting underneath still no go. Its in a very tight spot. It has been an absoulte nightmare. The last thing i want to do is remove the turbo. Im not that mechanicly minded and dont want more hassels. Has anyone been through this? I dont want to have to put it back together and pay a mechanic to do it. I want a win out of this. If anyone has run intonthe same problem and solved without removing the turbo please help thanks heaps. Ive given this a fair crack being a bloke not so handy. And im just after a win. Everytime i try to give somthin a crack on my car somthin pops up which stops me. But i want a win this time. It can stay on the stands and jack all week for all i care just aslong as i get a win im not fussed. Time to seek revenge on the 85% of failing to complete and endsup being a bigger job then 10 men could handle lol

Hears a list of tools ive attempted to use so far just to give you guys an idea of wherenim at or who may be in the same process or wanting to atempt
Tools used so far

*Lefty loosy righty tighty
-12mm single hex impact socket
-knuckle end
-rachet
-breaker bar
-wd40
-jack
-stands




Heres a pic of the inner engine gaurds removed for access
Image

The above nut over the stud is what im having trouble with which is the lower nut on the flange out of the 3. As you can tell ive caked in it wd40 to assist but its more of the factor of getting access to it to even get good leverage or a tool sitting on it properly which is whats killing me.


Image

Out with the old in with nothing lol
Yes no cat i will be getting 1 fitted *
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Re: Dumpipe removal - struck a nightmare!

Postby enthropy on Sat, 15 Dec 2012 8:07 +0000

I would say douse the problem nuts in wd40/crc/yeild and whatever products you can get a hold off.
I'm talking a whole can here!
Leave over night then hit it in the morning.
Did you say you've used a impact wrench already? (screwdriver you hit with a gimpy)

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Re: Dumpipe removal - struck a nightmare!

Postby Tys91 on Sat, 15 Dec 2012 8:11 +0000

Hey mate yer ive a impact socket. Not the wrench. Its sits tight but cant get a grip of it with a wrench or anything. Theres no room could only sneak in a qaurter tuen bur it slips due to not having proper leverage and things like the pipe itself in the way, steering shaft and brake lines
Its more the problem of access if anything . Im thinking about removing my steering shaft for more room? Its an absoulote drama. I really dont want to remove the turbo it should not have to come to that. Its horse crap.
Ive just run out of ideas.... i cannot figure it out

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Re: Dumpipe removal - struck a nightmare!

Postby packeteer on Sat, 15 Dec 2012 9:13 +0000

wd40 does a poor job at penetrating, I'd suggest something better

I used Pentr8 (from Repco). left it for an hour, then broke out the tools.
impact socket+uni joint+extension bar+standard ratchet+muscle

ps. it was my first mod, and I also struggled with a lack of mechanical skill.
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Re: Dumpipe removal - struck a nightmare!

Postby Tys91 on Sat, 15 Dec 2012 9:18 +0000

Where did you try it from? Too or side under quarter panel? Access is my only problem.
Its hard even sneaking a socket on the nut no room to move
Cheers for the tips fellas. Gona give it another crack in the morning

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Re: Dumpipe removal - struck a nightmare!

Postby packeteer on Sat, 15 Dec 2012 9:29 +0000

I did it from underneath the vehicle. yes, it is tight!
the uni joint+long extension bar were the key for me
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Re: Dumpipe removal - struck a nightmare!

Postby andy666 on Sat, 15 Dec 2012 10:35 +0000

Best bet would be a wobble extension. It's a socket extension bar with a rounded Square end on it so that the socket can wobble on it. Will give better access then a uni joint on a normal extension.
Then hit it with a rattle gun ;)
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Re: Dumpipe removal - struck a nightmare!

Postby benlux10 on Sat, 15 Dec 2012 10:37 +0000

You need to apply heat to the nut.
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Re: Dumpipe removal - struck a nightmare!

Postby mattwhite on Sun, 16 Dec 2012 12:37 +0000

Agree. Even one of those blue bottles with the torch on top. Quickly heat the nut before the stud can heat right up and expand too will free it up.
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Re: Dumpipe removal - struck a nightmare!

Postby amitch888 on Sun, 16 Dec 2012 2:07 +0000

Heat and uni joint is what I used. Its a prick of a spot to get to!

andy666 wrote:Then hit it with a rattle gun ;)


I'd be careful using the rattle gun, if it slips off which would be likely with things not sitting straight on, it will ruin the nut and then you will definitely be up the creek with no paddle
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Re: Dumpipe removal - struck a nightmare!

Postby Tys91 on Sun, 16 Dec 2012 5:23 +0000

Ok guys im gona give it another crack today
I wont use a rattle gun i cant afford any damage on this nut so il just go with a half extended bar and a uni joint il keep you guys updated

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Re: Dumpipe removal - struck a nightmare!

Postby hilder91 on Sun, 16 Dec 2012 5:33 +0000

mate i used to spanners put together under the vehicle to undo the bolt. also i used rust off before undoing it. ps if u can get a punch and hammer in there give it a couple of hits this might loosen it up.
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Re: Dumpipe removal - struck a nightmare!

Postby Alby on Sun, 16 Dec 2012 5:54 +0000

I used the wobble extension like Andy666 suggested but also started spraying it with Inox a few days before I put a spanner on it
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Re: Dumpipe removal - struck a nightmare!

Postby Blackie2008 on Sun, 16 Dec 2012 6:21 +0000

Couple of days soaked in CRC 5-56 and a spanner worked for me.
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Re: Dumpipe removal - struck a nightmare!

Postby Rocket55 on Sun, 16 Dec 2012 6:31 +0000

Yeap, this has been covered many times before with tried and proven results.

- Couple days of penetr8 or similar applied morning and night.
- Uni joint and extension bar or wobble bar
- Remove the heat shields.
- Plenty of Weatbix for breakie on the day.
- Apply heat to the nut if still havin g trouble.

Good luck with it.
Cheers Rod
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Re: Dumpipe removal - struck a nightmare!

Postby Tys91 on Sun, 16 Dec 2012 10:18 +0000

Well guys after a bit of patience and using the correct tools i finally have good news. I completed it. I ended up getting to the bottkm nut tighly wih a 12mm teng tools socket , knuckle for the angle around the header,extended bar on a rachet. I layed underneathbthe car jacked up ofcourse securely and accessed it. Soaked it in wd40 and then crack! Was like music to my ears havent heard a better sound lol brought me bloody victory. Well thanks to all who have given me tips and help i appreciate it what a wonderful forum we have here. This is what its all about i guess,blood sweat and gears! Didnt want to give up and i come up with a bloody win as my goal was to remove the bottom nut without having to remove the turbo, I hope this thread can assist others who go on to doing this.

Again guys
Thankyou! And merry xmas

New 3" dump pipe fitted tightly fitted
Image

Bottom nut *the hardest one to get to
Image

Old dump pipe
[/IMG]Image

Where my pipe ends. I will be getting a bend made up to extend it a tad more
Image

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Re: Dumpipe removal - struck a nightmare!

Postby Rocket55 on Sun, 16 Dec 2012 10:23 +0000

Nice work. :D
Cheers Rod
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Re: Dumpipe removal - SOLVED

Postby Tys91 on Sun, 16 Dec 2012 11:07 +0000

Cheers rocket!
With a bit of pateince i come out with a win. Not the most useful bloke with tools but i had a crack atleast

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Re: Dumpipe removal - SOLVED

Postby tulula on Sun, 16 Dec 2012 11:11 +0000

Inspirational stuff good onya mate!
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Re: Dumpipe removal - SOLVED

Postby StevenS on Sat, 16 Feb 2013 11:23 +0000

Plenty of WD-40, wobble rachet with 6 sided sockets, Butane torch even. These bastards just wouldn't come and then the nut heads got rounded.

Result see below. Still need to weld together the exhaust after this too!

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