Exhaust flange studs splayed; downpipe flange won't drop

[Landon427]

I'm attempting to drop the exhaust to remove the oil pan on my '99 SE (2.5L). The studs that connect the exhaust manifold flange to the downpipe flange are 'splayed out', if that makes sense (not parallel to the axis of the downpipe, but splayed outward at the threaded end of the studs). The downpipe flange is getting caught on the stud threads, and I haven't been able to get the downpipe flange past them. I've tried putting the nuts back on the studs and pulling the downpipe flange up to make sure it is parallel with the exhaust pipe flange, then slowly loosening both nuts and wiggling / prying the downpipe flange down, but as it approaches the bottom of the studs it just gets stuck on the threads. I've tried wiggling the exhaust (everything else is loose) every which way I can with no improvement, the stud spacing is just wider at the bottom of the threads and it's catching the downpipe flange. Any suggestions would be appreciated.

I know the FSM says you can raise the engine by removing the motor mount bolts, but I had to be different and try removing the exhaust... If I were to raise the engine, how does the 2.5L oil pump pickup tube come off? It would have to in order to get the oil pan off.

Thanks for any advice or suggestions.

 

[Chris]

Since the studs are toast, why not just get a cutting tool in there (if you can) and cut them off?

 

[Landon427]

I guess I'm hoping the studs aren't toast. I don't have access to a torch. I'm wondering if I can get a hose clamp on the unthreaded bottom of them and pull them in just enough to ease the flange down.

I don't have experience with exhaust studs. If I could cut the threaded section off, how difficult is it to press out the remaining part that would be stuck in the exhaust manifold flange? Thank you.

 

[Strizzo]

you can't bend them back? maybe an adjustable wrench on the flange to bend it back?

 

[Landon427]

I got the flange to drop by pounding on it some with a hammer. Hopefully I can clean up the stud threads with a die, and pull the studs in to parallel with a c clamp or something. Thanks for your help.