Ok guys..tell me im not losing it here.
yesterday zoomzoom and I took our shot at installing the ATR downpipe on my 94 PEP.
One of the studs holding the precat in (lower rear) was not a stud at all, but a bolt. In addition, it's thread size was 1/2", far larger than the other studs.
I checked the precat, and sure enough, one of the holes was larger.
The turbo manifold thread is also larger at that one area.

This creates a big problem with this downpipe. a) it's hole won't accomodate the larger thread. b) The bend on it makes it impossible to put a 1"x1/2" bolt in there (even a hex head).

I wouldn't be too concerned...but we broke one of the top studs (rear) so only about 1/2" of thread is exposes..just enough to peek pout past the mounting area on the downpipe.

So now ive got a great downpipe on...but only with 2 bolts....yikes!

Anyone's stock manifold/precat have that larger thread/bolt?

Any tips on how to solve this problem would be appreciated!
thanks
eric

 

I suspect that it had to be drilled out in the past, and was replaced with a larger stud. The hole in the pre-cat was probably drilled out to accept it.

You might be able to install a helicoil (sp?) thread insert that has a 1/2 outer thread, and use a smaller bolt or stud to connect the downpipe.

You will probably get leaks pretty quickly with just two fasteners in there, if you don't have them already. I had to run my car with three studs to get it to the shop to have the last one drilled out and replaced, but all was fine after that. You'll probably be fine, too, even if you have to drive the car for a bit before you get the other fasteners installed.

-Max

 

sounds like someone rigged it up for you follow max's advice

 

thanks guys...
i bet that someone was the dealer back in 95..i found a record of the orginal turbos being replaced.
damn dealers!
regarding the helicoil...will that screw into the turbo manifold 1st? if so...that means all must come down...correct?

and drilling out the broken stud....with ~1/3-1/2" exisitng, do i have a prayer of getting that out without removing the turbos?

i sure hope this downpipe is worth it...my stock precat is sure seeming good about now!

eric