How To Remove Exhaust Flange Studs


When your car needs repairs that include replacing or tightening parts, you have to get into it first to do so. If you try to take them out without lifting up the vehicle, you will most likely break something!

That is why having good toolboxes with you is important. Having appropriate tools for automotive work can save you time and money in the long run!

Luckily, we are giving you all the information here at our how-to article about the best way to remove exhaust flange studs. So, stay tuned and read on!

What are exhaust flange studs?

Exhaust flange studs hold your factory rubber gaskets in place by being pressed onto the pipe. Over time, this can cause cracks which need to be repaired otherwise water may enter the engine and damage it.

If there are too many cracks, then you should replace the whole thing because it could hurt your engine performance or even cause it to fail completely. Therefore, it is very important to know how to fix these properly!

Removing old exhaust flange studs

The hardest part of removing an old exhaust flange stud is getting it off of the old metal clamp. The easiest way to do this is using a hammer and some heavy weight (like a dumbbell). Simply bang away until it comes free!

Be careful not to hit the steel pipes hard as they can dent or crack.

Use a hammer and punch to break the flange studs

how to remove exhaust flange studs

The first step in removing old exhaust system components is to use a hammer and small diameter metal punch to smash each flange stud. Try using as many of these as possible before replacing the entire system!

It will take some time depending on how hard you hit the stud, but this really does work. Make sure to only strike at a smooth surface or the engine may crash to a stop!

Removing the catalytic converter can sometimes also require smashing it with a heavy object such as an ax head. Once again, be careful not to crack the catalyst chamber!

After breaking all the studs, you can now install new ones if needed! We have done this several times and have never had any issues doing so.

Use a hammer and cold chisel to remove the flange studs

how to remove exhaust flange studs

There are many different types of vehicle engines, but they all have one thing in common – you need to get out access to the exhaust!

That is to say, you’ll have to pull back the covers (or hood) or open up the engine compartment to gain entry into the pipes that eject burnt gases from the car.

By removing the cover(s), you will also be able to see the nuts that hold the two pieces of the pipe together. These are called flange studs.

Removing the old flange studs can sometimes prove tricky because there might not be any clear instructions for how to do it. Luckily, we have some easy steps here for you to try.

At The Parts Company, we make sure we only sell high quality automotive parts so we know our customers enjoy working with us.

Use a hammer and screwdriver to remove the exhaust flange

how to remove exhaust flange studs

The hardest part of removing these clamps is using the correct tool! Luckily, you can usually take your hand tools to any car shop and they will have a few sets that are for sure to work.

Most people use a small flat-headed screw driver as their main tool when trying to remove this clamp. This works well because it allows you to slowly push down on the head of the bolt while working your way up the shaft.

However, if this does not work then there are some heavier duty drivers that can be used. A heavy duty impact driver or even a sledgehammer would work just as well.

The only thing we recommend against is using a rounded end driver, like a putty knife blade edge one, in case something hard gets stuck inside the hole.

Use a blowtorch to remove the exhaust flange

how to remove exhaust flange studs

When your car is down, it can be hard to believe that it will start up again. That is why it is so important to know how to work on your vehicle!

If you are ever in need of help changing or replacing an engine part, knowing how to do it yourself is very helpful. Engine parts come with appropriate tools, so make sure to have those!

Removing old exhaust system components can sometimes prove tricky without the right tool. Luckily, we have compiled some tips for you here at In this article, we will show you how to easily remove the hex head bolts from the exhaust flanges on either side of your car.

Step one: Using a heat source, melt the plastic off the bolt

In order to properly pull out these bolts, you will first want to de-glutinate them. This means using a heat source to burn away any builtup gummy residue that may prevent the nuts from being able to slide onto the bolts.

Most people use a hairdryer to warm the plastic until it softens enough to pucker up slightly. Once done, you can run the nut/bolt combination through this area to see if it has melted into place.

Use a hammer and punch to break the studs

how to remove exhaust flange studs

The best way to remove exhaust flange studs is with a good old-fashioned hammer and metal punch. While some people use screwdrivers, we cannot recommend this as it may damage the surrounding area.

By using a hammer and metal punch instead of a screwdriver, you will also have better control over the pressure you apply to the stud. As you smash the stud down with a heavy object, it can be difficult to get a good hold of it unless you are very careful.

If you need to pull out an especially stubborn or rusty stud, then using a screw driver may be your best bet. But otherwise, just use a solid hit with the hammer! (Tip: For extra safety, wear protective goggles.

Use a hammer and cold chisel to remove the studs

how to remove exhaust flange studs

There are many different types of head bolts used in automotive assembly plants, but one of the most common is the exhaust flange bolt. These usually have either an internal or external thread that screws into or out of a larger hole.

Typically these head bolts are replaced due to corrosion or when they become too difficult to use. Luckily, replacing them is pretty easy!

To replace an exhaust flange bolt, you will need a pair of flat-head screwdrivers, a small metal brush, and a nylon bristle tool. You can get these at any auto parts store for around $5–$10 each.

The nylon bristle tool is best to use because it has very fine hairs which help pick up excess rust and grease from the threads. This helps prevent clogging and thus better engine performance.

Use a hammer and screwdriver to remove the exhaust flange

how to remove exhaust flange studs

When trying to remove an old style exhaust flange stud, you can use hammers or a regular screw driver to do so.

Most vehicles have several brackets that hold up the catalytic converter. These are usually called exhaust flanges. On some cars these will be attached directly to the engine bay with bolts, whereas other cars use longer pipe pieces as an elbow before they connect to the final product.

The problem most people run into is that when they try to take off the flange, it does not want to come out easily. It may even break off in your hands if you pull too hard! This is totally normal, but unfortunately difficult to remedy without buying new parts.

Luckily, there are tricks you can use to get this done cheaply and quickly.

Use an angle grinder and grinding wheel to remove the exhaust flange

how to remove exhaust flange studs

The next step in how to remove exhaust flange studs is using your angle grinder to break down the old steel. You will need to use a good quality grinding disk or abrasive pad for this!

We recommend using a small amount of carburetor cleaner with no alcohol as the solvent. This will prevent oxidation and corrosion of the metal parts, which would make re-melting more difficult.

Once you have cleaned the part, use the edge of the angled plate as a place to weld the new piece onto. We suggest using a filler rod made of stainless steel to help protect the area from rusting.

General tips before welding: Make sure your welder has enough power to properly melt the new material and that it does not burn away too quickly.

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