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Old 11-14-2011
Thread Starter
Join Date: May 2009
Location: Hazleton, PA
Posts: 216
Replace it or not?

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.
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Replace it or not?-exhaust-1.jpg   Replace it or not?-exhaust2-1.jpg   Replace it or not?-exhaust3-1.jpg  
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Old 11-14-2011
djfllmn's Avatar
Join Date: Mar 2009
Location: York, PA
Posts: 5,796
id say replace it but in that 500 are the cat prices included?...cats can be pretty salty
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Old 11-14-2011
rolsmojave3's Avatar
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Join Date: Jun 2006
Location: Wisconsin
Posts: 2,852
Torch the rest of what's there out so you have a hole. Then use zinc coated bolts with anti-seize.
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Old 11-15-2011
Thread Starter
Join Date: May 2009
Location: Hazleton, PA
Posts: 216
Originally Posted by rolsmojave3 View Post
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.
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Old 11-15-2011
Kris03's Avatar
Join Date: Jun 2011
Location: glastonbury, ct
Posts: 1,236
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.
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