BlackSaharaJLU
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After replacing the intermediate pipe a few weeks ago after it cracked right before the forward clamp, my wife told me that the Jeep was loud and making rattling noises again. I was expecting that some of the clamps I installed just needed to be retightend, but that was not the case. Unfortunately, both bolts that connect the Y pipe to the catalytic converter on the passenger side rusted completely through. Typically, this would just require a couple of new nuts and bolts and you would be good to go. However, Jeep decided to weld the nuts onto the back of one of the flanges and its in a location where there is no easy way to drill them out. Fortunately, I found a company (Nickson Exhaust) that makes a 2.25"-2.5" split flange so all I needed to do was break the original flange free (from the rust), rotate it 180 degrees and then grind ~ 1/2" off one side of it. This allowed the bolts to easily pass through the split flange and the exhaust is now back to good. It's certainly not a pretty fix, but I wanted to share in the event that it may help others.
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