mt6127

I started the task of removing the catalytic converter to get access to the O2 sensor - but the bolts are rusted beyond believe... so I cut through the first one between the cat and the header. The nut side fell off but the bolt head side on the exhaust header stayed in the collar like its welded in there even after wacking at it with a drift. Sanity check here - the bolt isn't welded to the collar and I am not doing anything stupid by cutting all the bolts between the cat and header?? (late, tired, lost confidence...)

powerkraut

many moons ago when i replaced my exhaust, i had to do the same. it just takes some coaxing. i did it in my usual low-class way, and just cut and hammered and swore until it gave up, then replaced it with some new metric bolts and nuts to the tune of about $2.50 IIRC. be sure to use anti-seize or the like so the next time you dont have the same problem'

AudiSport4000

Changed out the ol cat coverter on my 4k, didnt have that much of a problem. Did notice a decrease in power though, after the new one was in.
For the 4kq, I had to cut the bolts off with a cutting wheel, and I simply got new ones at the local hardware store. Sometimes cutting is the only way!

Mike

mikescoupegt

My car came catless, but if you have already cut the nut off, try to heat the bolt part until it is red. Once hot, you should be able to get a drift and tap it out. IF that doesnt work try to drill it out. Then you can retap the hole after for the new cat if need be.

RallyXAudi

<img src="http://www.pbblaster.com/store/images/PBCatalyst.gif">

<b>http://www.pbblaster.com/</b>

mt6127

I've been using blaster for years. Good stuff.

PJM99

Let PB soak in there, try to use heat or just cut the thing once you get more confidence. Exhaust system are always a PITA.

RallyXAudi

I swear by it.

mt6127

and to see if there's a bigger cutting wheel for a Dremel...

JeromeS.

Its just three bolts with nuts\washers on each side. Correct me if wrong, but thats the only setup I have seen.