Need Help removing y-flex pipe from 2004 Sorento - Kia Forum
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#1 (permalink) Old 04-06-2011, 08:10 AM
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Default Need Help removing y-flex pipe from 2004 Sorento

I have a 04 Sorento and need to replace the Y-Flex pipe between the manifold and the Catalytic Converter. My issue is the bolt and nut that connects the converter and Flex pipe is so rusted and formed together I can't seem to figure out how to get it out. I'm not sure if the bolt is factory welded into the converter or not. I don't want to ruin the converter because that would be an additional $800 for something I don't need to replace. Does anyone have any suggestions on how to remove this bolt? I am thinking if I am going to break the bolt and then just drill out the existing bolt out of the converter and put in a stainless steel bolt and nut.
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#2 (permalink) Old 04-06-2011, 08:29 AM
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Welcome to the forum. Thanks for the pictures, They do help incredibly. The hardware on the flex pipes always do this. Poor material quality. The threaded studs are part of the converter. What I always do is find which size I need (box end wrench). Usually the sizes vary due to the corrosion. Once I have the sizes I need I bring out the torch. Heat up the nuts a little. Then just work them with the wrench. Do them one at a time, and also be careful with the torch (space is a little confined up there). When I replace the flex pipe I replace the hardware 99% of the time. Don't forget the gaskets.

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#3 (permalink) Old 04-06-2011, 08:37 AM
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Matt
Thanks for the advice. I wasn't sure how to do this because when I looked online most of the pictures replacement converters don't have the bolts in them. They show them as having just a hole to put a bolt through. Then other pictures show the converter with a bolt it in. I am going to try the torch option then. I have also read online that they suggest also using a nut splitter, because it saves a ton of time. They say whether you use a torch or nut splitter the nut needs to be replaced anyway.
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#4 (permalink) Old 04-06-2011, 10:56 AM
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I have never used a nut splitter, but that could also work. Also, in regards to removing the O2 sensors.. Usually I remove the sensors from the pipe, leaving them plugged in. You could also unplug them, leaving them in the pipe and swapping them over outside the car. Either way.

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