2.5L Exhaust Bolt Sizes

sheltonfilms · #1 02-09-2014, 07:24 PM

Getting ready to remove my catalytic converter pipe on my 2.5L to fix a rattling heat shield and leak (gonna weld everything).

I've already got the CC pipe to muffler pipe unbolted, I just need to get the two bolts that hold the CC pipe to the exhaust manifold off.

I've been PBing the bolts for the past 3 days and tried breaking one loose through the wheel opening. The breaker bar moved but the other end of the bolt appeared not to move. I decided to stop before that bolt breaks all the way and shuts my truck down for a few days.

I'm almost 90% sure those bolts from the manifold to the cat pipe are gonna break. This will probably leave me with unbolting the exhaust manifold to extract the broken bolt.

Question: What sizes are these two sets of bolts?
1. Cat pipe to manifold (2 bolts)
2. Exhaust manifold bolts (8)

Anyone have Dorman part #s they know work?

atikovi · #2 05-04-2016, 07:22 PM

So what happened? Did ya break those bolts? I'm in the middle of this. Broke both bolts a few days ago. Just got the manifold out tonight.

sheltonfilms · #3 05-04-2016, 08:51 PM

Here is what the final result was, lots of info for ya:

Exhaust manifold difference

atikovi · #4 05-05-2016, 05:33 AM

Yep a replacement manifold would be the way to go but I'm going to try and remove the broken bolts first.

sheltonfilms · #5 05-05-2016, 06:06 AM

I replaced the manifold because I got one bolt out, using torch. And the other I broke an HSS drill bit off in it. At that point I said screw it.

atikovi · #6 05-05-2016, 07:13 PM

Tried to drill into one bolt and either they are made of some super hard kriptonite alloy, or a half dozen of my drill bits are all worn out. Said forget this. Went to my backup plan for which I had already ordered a pair of Studfix repair studs. Got everything together loose and will align and tighten tomorrow.