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Discussion Starter #1 (Edited)
Like the title says, anybody know off the top of their head what stud size/thread pitch the hardware holding the cat assembly to the exhaust manifolds is? Somebody had it apart before I purchased the vehicle (apparently), and left a couple of the nuts off. Now the studs are so corroded that I cannot get any nut to go on there, and I have a decent exhaust leak that I'd like to get fixed (maybe it's part of the reason the car is running like crap). I'm thinking that the best option is to drop the catalytic converter assembly and replace the studs that hold it all together. As of right now, there is only one nut on each side holding things together, be nice to have two per side....

UPDATE: The stud/nut sizes are M10-1.5 x ??mm long. See my post below for link to the kit.
 

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Like the title says, anybody know off the top of their head what stud size/thread pitch the hardware holding the cat assembly to the exhaust manifolds is? Somebody had it apart before I purchased the vehicle (apparently), and left a couple of the nuts off. Now the studs are so corroded that I cannot get any nut to go on there, and I have a decent exhaust leak that I'd like to get fixed (maybe it's part of the reason the car is running like crap). I'm thinking that the best option is to drop the catalytic converter assembly and replace the studs that hold it all together. As of right now, there is only one nut on each side holding things together, be nice to have two per side....
Can you run a die on the threads? That is what I would do.
 

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I just put new bolts nuts and washers on mine. Not easy to get ur arm up there but with a little patience and creativity (if I remember correctly I may have used a bit of gum to hold the washer on the head of the bolt :D) you can get it together.
Took me a bit of testing to find the right size of bolt to fit best.
 

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Discussion Starter #4
You're not gonna believe this....

Well, I figured out the stud/ nut size question, and I'll post the specs below for others who might be curious. I also found the exhaust leaks. Plural. Both sides. Apparently, someone in the past decided to use a cutting torch/welder/unknown device to blow two 3/4" holes in the top of the pipe about 3 inches or so downstream of the rear O2 sensors. Holes neatly melted through the pipe, nice and symmetrical, obviously intentional. I'm guessing to give the car a little "rumble". Well, it sounds like a huge exhaust leak to my ears, so I guess I now have an excellent excuse to go buy some exhaust goodies from Mandrel Exhaust Systems....

I (temporarily) plugged the holes as a test, and the 3rd cat doesn't seem to be plugged up, which is the only reason I would do something like THAT, and only as a temporary fix until I could deal with a plugged 3rd cat problem CORRECTLY. Arrgh.

Anyways, about the stud sizes...

Went to Checker/Schucks/Kragens/O'Reilly's, and found this kit. It's Dorman Help! Products number 03131, exhaust flange hardware kit.

The stud sizes (in the kit) are M10-1.5 x 72mm, and I've already gotten the bolts loosened up without stripping/breaking/rounding off anything. Took me all afternoon, too. So, tomorrow, I go put in new studs and two exhaust clamp patch thingies to cover those bloody holes. That should tidy things up until the 'Bird gets an exhaust makeover in the next two or three months
 

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Discussion Starter #6
Huh? Is that the result of some big merger clusterhump or something?
More or less. I've noticed that they're called by the different names (Checker/Schuck's/Kragen's) depending on where you are, but the whole mess (CSK Auto) was bought by O'Reilly. www.oreillyauto.com in mid-2008. They just made the "official" changeover recently, both the actual stores and the website, and as a result all my bookmarks for various parts from Checker suddenly don't work anymore.... Oh well, time to redo 'em, I suppose.
 
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