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Discussion Starter #1 (Edited)
Hey all, I'm replacing the Y-pipe/cat-converter assembly on my sister's 1996 'Bird (4.6, all stock), and have a lot of broken studs at both ends.

I'm hunting down some new fasteners, and RockAuto shows only one stud kit: Fel-Pro ES75104. It's called "Exhaust Flange Bolt Set", which sounds like it should be for the flanges that I'm working on. But it describes the stud dimensions as M12x1.75x62mm. What's left of the old studs are terribly rusty, but as near as I can tell, I'm pretty sure they're all M10, not M12. I tried to look up the ES75104 kit on some other sites, but they're all claiming that those studs are M12, leading me to believe that it's not a typo. Is this even the right kit?
 

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Can't help you on the size/thread of the bolts. I did go through this on my Cougar this summer. Have you got the old ones out yet? They were pretty hard to drill out. I ended up doing a combo of grade 8 bolts/nuts and not using the studs.
 

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I haven't posted, because I'm not sure. :zdunno:

I only have a set of Mark manifolds loose, and those are 10mm, I'm pretty sure.

They are not 12mm. 12mm is the size of the lift bolt holes on the side of the engine, and those are bigger.

I'll try to look tomorrow, it's supposed to be not raining, and I'll be under there.
 

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Discussion Starter #4
I haven't removed the broken pieces from the flanges yet, but I highly doubt that the stud would be a different size where it screws into the flange. The part that's sticking out is definitely M10x1.5. The front studs are about 60mm long, and the rear ones 80mm.

I'll see what I can come up with locally instead of taking a chance on ordering a kit.
 

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It's 10mm; I found one in the garage.

The one I found threads into the manifold, with a short section, with a depth limiting feature.

I think the last ones I got were dorman; advanced or AZ should have them locally.
 

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Discussion Starter #6
Yup, 'Zone had a Dorman pack on the rack- #03133 includes 6 studs and 6 flanged nuts. They're not long enough for the rear connection though, so I picked up some regular bolts to put that back together instead. Should work.
 

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Something I learned; DON'T put stainless steel with non-stainless stuff; it rusts everything else, lol.
 

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Discussion Starter #8
Yeah, some kind of chemical reaction IIRC.

BTW, I did contact Federal-Mogul/Fel-Pro, and they confirmed that the studs in the ES75104 kit are indeed M12x1.75x62mm. Not only according to FedMo's own database, but those are the actual dimensions. So the typo was in the application list after all.

The closest thing they have to the correct dimensions would be the ES75105 kit, which comes with 4 studs and 4 nuts, all M10x1.5. At 72mm, they're a little long for the front flanges (which might interfere with using a deep socket?), and a tad short for the rear flange. The studs in the Dorman 03133 kit are 62mm long, which is a lot closer to the original front flange stud length.
 

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I think I used the Dorman one, on the one I broke.

I hit one with an impact, and it just crumbled; but it was the one that threads into the manifold; the one in the y-pipe was solid, and not even rusty.

The one that broke is the one I always seem to punch, taking out a transmission; I may have bled on it, lol.
 

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Discussion Starter #10
Say, while I'm thinking about it- what's the best method for reinstalling the Y-pipe?

I seem to recall having a hell of a time getting it back in several years ago when I rebuilt the transmission. Somehow I eventually weasled it back into place. Removing the pipe again this time around, it was a super-tight fit, flexing the hanger sleeve bushings under the tailshaft like crazy. I don't know how I'm gonna get it back in. Does the transmission have to be lowered?
 

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I haven't been checking the site very often lately. So you probably have this all back together and fixed by now.

On my 95, I had good luck with the Dorman 03133 kit. And I had to remove the two rear O2 sensors for clearance to get the Y-pipe back on.
 

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Discussion Starter #12
Ended up bending the posts that slide into the bracket bushings just a little. Hated to do that, but it worked. Shoulda tried removing the sensors...

It's back together now, but not completely. Sister couldn't wait to have all the studs swapped out, so it's still missing a couple. It's secure for now, but leaky. Trying to schedule with her to get back under it again. At least her commute route doesn't have her sitting still in traffic very much.
 
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