2000,S40,Second(rear)Catalytic Converter Removal

[uhlan]

My S40 has ~130K miles. Exhaust system is almost in excellent condition. Problem is the rear (second) catalytic convertor. The one with the more or less flexible portion. The flex portion has become disconnected from the solid piping behind it. This complete second catalytic covertor section therefore needs to be replaced. The rear portion of this section is not a real problem. I can work it out of the muffler section without " too much swearing & cussing". Problem is the front portion of this section. There is a square bracket /flange that has 4 holes the accepts 4 bolts that are inserted into another a square bracket /flange in the rear portion of the front catalytic convertor section. The nuts and bolts on the rear convertor section are rather deeply rusted along with the threads. I'm afraid that I will have to cut these nuts and bolts off. Problem is that when I try to feel for the heads of the bolts on the front catalytic converter side, I don't feel any? Is this possible? Could these bolts actually have been "head less" and threaded into the bracket of the front catalytic converter bracket? If I have to cut the bolts in order to seperate the front and rear catalytic convertor brackets I can be in some real difficulty when I go back to try to bolt these 2 sections back together. Will I need to drill these out and replace with headed bolts? How were the bolts inserted in the front bracket? Will I be doomed to replace both catalytic converters and be better off trying to undo the system from the engine manifolds?

Help!!!! Geeze the Exhaust system on the S40 is really pricey!!!!

[MadeInJapan]

I just looked at the parts catalog for your car and indeed those bolts you speak of are headless...they have threads on both ends. If you really have to get them off I would try some PB Blaster (penetrating oil) and possibly even heat the stud that's sticking up to try to get them out. Don't worry about buggering up the threads...use a pipe wrench if you have to...they should come out. the replacement part number for those studs is #978342 (part #26 in the diagram below) assuming we're talking about the same part and you have a turbo car (I believe all were in the U.S.):

[MadeInJapan]

If everything is beyond you and you have to replace some exhaust parts, I would give www.erievovo.com a call tomorrow. You can email them but it might be a week before you hear back. Good luck and keep us updated.
MIJ