I noticed one of the bolts that hold my 42 DD downpipe on my 225 TT was loose, so I tried to tighten it only to have the bolt break in half. It's one of the ones at the flange right after the downpipe exits the engine. In other words, the one that is really hard to get to. What's the best way to get up in that area and try and clear the broken bolt?

 

no real easy way

if you cant get to it with the dp off then pull the turbo.

 

The way I did it before replacing the hardware (use to always come loose there) was to remove the strut bar and o2 sensor. This way I was able to get my hand and a small socket wrench thru the larger space. I found it much easier than going thru the bottom and I didn't have to Jack up the car.

 

Took care of it. Mobius97, your advice was a lifesaver. I thought the bolt was stuck, but I forgot that the bolts just after the turbo are pre-threaded on the 42DD downpipe, and I was trying to tighten a bolt that was already threaded in. I replaced the gasket and the broken bolt, and got everything back together. The sound difference is incredible. My car finally sounds like a sports car and not a tractor. The performance seems to be increased as well, possibly due to the O2 sensors adjusting air/fuel correctly now that there isn't a 1/4'' exhaust leak.

 

Okay, it sounded good for a day and then came loose again. I've searched this forum and read about replacing the hardware, but how am I supposed to replace the bolts on the flange right after the turbo if they are lock-tighted (or whatever 42 DD uses) in? I also read where cincyTT recommended just running without a gasket since the build quality of the 42 DD is high. Anyone have experience with this?

 

I like gaskets.....cincy doesnt..... personal prefrence, there is not a right or wrong answer there but most you will find do run them. I went thru this same thing you are going thru....trust me, I got good at swapping out the gasket and replacing/tightening them back down to a "T". Find a good gasket, good hardware with locking nut and washer hardware store or go online to JEGs and order some hardware and gaskets. After I did this I ran for a year or so w/o a problem. She was still going strong when I traded her in for me Lotus Elise.


liquid wrench or PB blaster is your freind! Spray good and let it really soak in for a bit....go back and spray again....

 

i dont like gaskets cuz i blew mine out and ever since i removed them i have had 0 issues. I still am using the steel one that connects the turbine to the dp though.