Hey all...

I hope this will be my last new thread in searching for answers. As soon as my parts arrive tomorrow, this beast is getting put back together.

Ok so I have an 02 FX4, twin stick 5-speed with 88K.

Here's my latest (and hopefully last) dilemma.

I had to cut the bolts off to get this beast off (in order to access the right-most bolt on the transfer case) with a torch to even THINK about removing it.



Now, the bolts in this pic are actually pressed-in studs that aren't meant to be removed:



I attempted to blue wrench the one on the top and the whole stud broke.

These were the spring bolts (which, had to be cut off, as well) and while I was able to find replacement bolts, I'm not sure how to get the ends off:



I was talking with the dealer about this. I asked if I should be hearing things rattle around inside and their blatant answer was "NO!" Well, it sounds like a babies rattle in there.

So, should I replace this or try to salvage it all? I really DON'T have the $1500 the dealer wants for the part, however, I'm pretty sure I can get a full cat-back system for around $500. Not that I really have the cash for that, either, but it would outlast the life of the truck.

 

id say replace it but in that 500 are the cat prices included?...cats can be pretty salty

 

Torch the rest of what's there out so you have a hole. Then use zinc coated bolts with anti-seize.

 

I just might try that.

....only because I really don't have the cash for a full cat-back system right now.

 

just my 2-cents-usually cat-back systems do not include the cats. they can be pretty expensive.
cat backs are usually from the last cat to the tip. so some piping, tail tips, and a muffler.

other options: junk yard, gut them, straight pipe.