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Discussion Starter #1
I got started taking the catalytic converters off our 2003 Pathfinder today. I got the exhaust with the muffler and rear cats loose and one rear cat off. Taking the heat shield off the front passenger side cat, all the 10 mm bolts came out except for one bolt and it was in the hardest place of all to get too. It is about 9 inches up in there and on the back side of the front converter which is about an inch from the firewall.

The bolt head rounded, I was using a 10 mm gear wrench that is all that would fit in there. A regular 10 mm might have worked but no way to see the bolt to remove that way. I have tried to rip the heat shield off with no luck, that sucker is double thickness. The only thing I can think of is to make a long chisel and cut it off. I have an old star drill that I can sharpen and use as a chisel, that is about all I can think of. Maybe make a wedge that will fit each side of the bolt from under the shield, like a ball joint wedge. Any suggestions to get it off?

Question, I can see inside the back side of the front converter, it is snow white on the back side, is it usually dirty looking if bad? Also two of the 02 sensors were only finger tight, aren't they supposed to be tighter than that?
 

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Discussion Starter #3
If you can get in there with a torch, heat the bolt and the area it screws into to a cherry red appearance; it now should come off easily.
Thanks rogo, I appreciate your response. The problem is I can't get a torch within 6 or 7 inches of that bolt, it will be all I can do to get a socket and extension to get the converter off, it is really tight in there. You can't even see the bolt, you just have to squeeze your hand in there and feel for the bolt.

I did find my old star drill this evening and reshaped it into a long chisel, I will try that tomorrow Lord willing. When I put the cats back in, I will install the shields first but I will drill holes so I can get to the cat to manifold bolts without removing the shields again.
 

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Discussion Starter #4
I finally got the heat shield off the catalytic converter this evening. The heat shield is totally ruined, no way to reuse it. I had to cut pry and beat it to get it to come off. I got the converter off and it has started to deteriorate so it will be replaced. My main concern right now is where can I buy another heat shield. I don't need the bottom half I need the top half on the passenger side. Any suggestions where I might buy one?
 

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If you want another heat shield, the dealer is the only place that will...or, rather, "might"....be able to get a new one and it will be expensive. Used one from a salvage yard is your other option.
 

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Discussion Starter #6
smj999smj, I appreciate your suggestion, I did find a complete set on ebay for a reasonable cost.

I decided to try to beat the shield back into shape on the old converter. To my surprise I got it back to pretty good shape. The tear was only about 1/16 open, so I bought a muffler wrap with some type of heat resistant clay and wrapped the converter, put the shield back on, then wrapped the shield also. I had two large hoes type clamps and clamped them on the wrap and pulled the shield tight, I hope that will work.

I did finally get the other side cat on and also the other 02 sensor, I worked for three hours trying to get the shield on that goes against the frame, no luck. 15 minutes after I got in the house for the evening, it dawned on me how to get that blame shield on. I will cut the heads off three of the small screws and insert them into the holes on the converter, wiggle the shield around until they were on the studs, then remove the studs one at a time and replace with a screw. I wish I had thought about that last evening. This getting under the truck is killing me. lol
 
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