Me and my buddy made our first mistake the other day by taking off the the cat and all that comes with it, muffler, tail pipe.. Anyway the bolts on the flange are frozen in there and well we cant get them out now and cant get the system back on. It was all fun and games with the louder truck but my gas milege went to hell and it got annoying now. Any ideas.

Oh before I forget it is a 94 ford 250 with a 5.8 in it

 

These are the bolts into the flange on the exhaust manifolds?

Or other flange?

Either way, are the bolt holes blind or open all the way through the flange?

If open, try to soak from both sides with Liquid Wrench or other fine brand, otherwise just pour in on there.

Next, find an easy-out of the proper size, and a carbide tipped reverse rotation drill to drill the bolts with.

Get out the goggles (glasses will allow chips etc to bounce around the glass and find the middle of your eye) and start drilling.

Good luck.

 

torched the bolts out, going to drill the rest out then grind off the tops AND never doing that again. I can only imagine the s&!# i did to my motor or my exhaust valves.