How to Remove Rusty Exhaust Pipe Bolts

Written by brian osher
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Removing rusty exhaust pipe bolts can be a frustrating task, but it does not have to be. Exhaust pipe clamps and exhaust pipe bolts are cheap, so there is no reason for you to try to salvage them. You can purchase nut splitters for about £6 at most automotive parts stores. They can last a lifetime for the typical home mechanic and will save time and money compared with other rusty-bolt removal methods. Nut splitters don't have a flame and don't create sparks, so there is no need to worry about gasoline or other flammable substances under the car.

Skill level:
Moderately Easy

Things you need

  • Nut splitter
  • Adjustable wrench
  • Flat screwdriver

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  1. 1

    Put the nut splitter over the exhaust clamp nut to be cut. Locate the nut splitter's cutter over the centre of one of the nut's hexagonal sides and tighten the nut splitter in place by hand, turning counterclockwise. Continue tightening the nut splitter with an adjustable wrench until you visualise the cutter has completely sheared through the side of the nut.

  2. 2

    Loosen the nut splitter and remove.

  3. 3

    Reinstall the nut splitter over the nut. Locate the nut splitter's cutter on the hex side opposite from the side split. Tighten the nut splitter in place by hand and continue tightening until the nut is sheared.

  4. 4

    Remove the nut splitter and remove the nut halves from the bolt by prying with a flat screwdriver.

  5. 5

    Repeat Step 1 through Step 4 on the other exhaust clamp bolt and remove the clamp from the automobile.

Tips and warnings

  • Allow the exhaust to cool if the vehicle was driven recently.

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