










Cat back exhaust swap going downhill with gusto
Purchased the BRExhaust 2005-2012 Nissan Pathfinder 4.0L Direct-Fit Exhaust System Kit 106-0066.
My OEM one with two mufflers was shot out. Just wanted to do a quick swap over the weekend and I’m getting my butt kicked.
Was ready for tight bolts on the cat flange but this was otherworldly for me.
Used my torch and PB Blaster back and forth trying to shock it etc, used my air scaler to break the scale away and shock the stud, wire wheeled it to be safe, and nothing was working.
Finally had to cut them but even then I could t get the stud out of the cat flange. Took an even closer look, and I could be wrong, but I think they were welded in to the flange with a stud gun or something.
Decided to just drill them out since the kit has bolt through hardware.
Got most of one but the others I’m making almost no progress. Tomorrow I go get new drill bits and trudge the road.
But now I look at the new pipe/flange compared to the cat outlet, and they’re almost 3/4” different in their ID.
Am I just dropping the ball on doing my part, is something not right, or is this standard for these 3rd party kits and it’s nothing to worry about?