Well today's the big day. Me and a buddy are going to pull off my cross-over exhaust and install the Fallsac set I purchased. For the past two days I've been soaking the exhaust stud nuts with PB Blaster penetrating oil so hopefully the nuts will come off without any trouble. They have never been off since new, and its a '02, so they are pretty rusty so I was wondering if anyone had any tips that may help me get them off without any problems.

Thanks and say a prayer for me on this project......[sm=feedback.gif]

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You've done the right thing by soaking them - they should come off without any trouble. Remember to use a torque wrench when re-installing them - 120 in/lbs I believe - tighten alternately a little at a time.

 

The PB should work.

 

they will come right off
just did mine in november

 

Hopefully you haven't been riding around the past two days, right? They might already be off by the time you start your project! [sm=escape.gif]

 

Be careful!! After soaking mine and trying to remove mine one in the rear head SNAPPED off in the head, ended up having it machined out.

 

Wondering the same thing. Wonder if worth running engine after soaking nuts - to heat up the studs / nuts. Either that or cut the nuts off - if you can get in there.

Any case, I'm going to soak and heat - when it comes time for my build.

 

Hurry!!!

Soaking the exhaust studs with PB Blaster for the past two days did the trick. The nutscame rightoff without any problems. In fact I soaked all the clamps also and theyalso loosened up without any problem. That PB Blaster is some great stuff...

Thanks for all the input guys, I really appreciate it...

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I just removed exhaust stud nuts that were VERY rusty and on a 1992 today. I've got a mini torch that can focus on just the nut. I hit the stud with liquid wrench , soaked for a few hours, then turned the nut until it started to tighten (a pending SNAP). Then reversed it back on a turn or two, LW'd it, heated it for 15 seconds with the torch, tried it again and again until the nut spun off. Once a stud unthreaded from a manifold using this approach -- it would have snapped for sure. two others were borderline snapping . Thankfully, now we're looking for new nuts and one stud instead of worrying about a broken one. I'm not big on re-using exhaust stud nuts.

Let us know how easy it was to tighten that rear-lower nut with those pipes. Did you go with the flat or cone exhaust gaskets?

 

Wow Roadkingon you had a hell of a day. Glad to read you were successful in gettin your nuts off. LOL.

I will be installing the tapered (cone) Harley gaskets when I put the exhaust back on. My buddy, who helped me today, picked them up for me and insisted we use this kind instead of the flat ones. He feels they do a better job of sealing the pipe to the head so who was I to argue...

Ride safe...