I'm changing the bad cat on my '02 3.8 SS. Despite many cycles with the torch, PB Blaster, and even the old wax trick, (and despite the car having never seen snow), I broke one of the two bolts at the rear converter flange.

Is it worth buying a stud extractor, or is that unlikely to remove the rusty looking leftover end of the bolt? I don't have one, never needed one so far, but I'd buy one if it might work.

Is the only other option to drill and re-tap?

Also, haven't started on the front bolts yet, but they sure look like they're in a bad place to break a bolt. Does anyone know if they're less likely to break?

Thanks.

 

It sounds like you've tried a lot of the same tricks I would have used. At this point I think I'd drill it out for the largest size extractor I could. Then I'd heat it up and give it a good soaking of penetrating oil. After it completely cooled I'd give it a healthy swing from a BFH, then use the extractor. If it doesn't break free after that drilling/tapping may be the only choice.