? on removing stock exhaust

[K_Arts]

Ok guys... I am trying to remove my stock exhaust to finally put on my Jardine, but I am having issues. How did you guys get off the stock exhaust? This thing is Clamped down TIGHT!!! I have the clamps removed, but I can't budge the pipes loose. I am about ready to start cutting the hangers to get this blasted thing out. But I am kind of afraid to due to the fuel tank being about a foot to a foot and a half away. I don't want to see sparks and blow myself up in my driveway... LOL... I at least want to hear the truck with the new exhaust on once... LOL



Any Advice would be awesome... Thanks



kev

 

[BIG BOB]

Sawsall (reciprocal saw) and metel blades is what I used (cut in 2 places). I wasn't going to save the stock exhaust anyway.

 

[WYD]

Use a sawsall and cut the 3" pipe under the cab and have a muffler shop fix a coupler (union) to clamp back together. At this point you should be able to unbolt all the hangers and remove the exhaust. I then unclamped the resonator from the muffler (4") pipe and sawed it off again. and chiseled out the pipe inside the muffler.



I left the resonator on and had a short piece of 4" and a 4" tail pipe made to exit the truck in the same place as the original.



We used round rod that fit throgh the rubber grommets and welded them to the pipe.



This system can be unbolted and the original can be fitted with little work if for some reason you don't like it w/o the muffler

 

[EMDDIESEL]

SAWZALL!!!!!!!! You can do anything with a Sawzall!. My absolute favorite tool, next to Duct tape of course. Seriously, i took mine out on the ground in 30 minutes with my trusty Sawzall.

 

[work2muchplay2little]

kev, I took mine out in two pieces without cutting (just in case) by removing clamp in front of resonator and using a short piece of 2x4 against the resonator and a 5 pound short handled sledge, hammered it apart. Pulled the down pipe out through the top and the remainder forward over the axle.

 

[Fuzz]

Kev,

Any exhaust is a "PITA" to work on. But mostly "grunt" work as you are finding out.

I am committed to help on rewiring a Jeep for trailer lights this AM or would offer to drive up.

If you aren't tore apart yet ,and would like to come out I have some equip might help on the job ie,sawzall,welders,both electric and gas. If not today could come up to your place on Sun.

Fuzz

 

[Alaskaskiff]

I loosed the fittings and chained one end of the exhaust to the skid plate and the pulled the cat towards the rear with a chain binder to separate the joint. Once the first piece is out it gets lots easier.

 

[K_Arts]

Thanks for the offer Fuzz, I really appreciate it.



Here's where I am. I currently have the clamps all loosened up, and some of the hangers cut (so the pipe is still somewhat permanately attached to my truck). I figured that I should probably loosen up the 2 bolts at the down pipe that connect to the exhaust elbow before I got ahead of myself. But them 2 bolts will NOT brake loose. I plugged in my compressor to get out the air ratchet, but it just can't produce enough torque to break them bolts loose. I treid WD40 hoping it would maybe help... but NOPE.



Any ideas on what I can do to loosen up these bolts? If I can get them out then I'm in the clear.



Thanks guys.



Fuzz. . if I can't get these things out do you happen to have an impact gun that may produce enough torque to loosen these things up? If so, I may head down your way if you don't mind and have some time.



Again Thanks



Kev

 

[Archive]

Okay, you may have tried this... put a couple of extensions on your breaker bar, come at these bolts from the bottom, then put a piece of pipe on the breaker bar. Have someone hold the socket on the nut from above. With the pipe on your breaker bar, you should be able to pop about anything loose.

 

[K_Arts]

Rob... . thanks for the advice. I am on the way to the hardware store to buy some extensions. Unfortunately, after moving into the new house, I can't find a lot of my tools. I can only locate 3 little 3" extensions...



Geesh... guess I gotta go buy new tools... . LOL



Kev

 

[Fuzz]

Kev,

Check your Email. . sent the directions to the house if you decide to come down. . also some other ideas

Fuzz

 

[Koa Man]

When you put on your new exhaust do not use the guillotine exhaust clamps like the factory does. Use band clamps, which seal better and won't put a crimp in the pipe. That way if you ever have to take it apart, it will be a lot easier. I know you can get 4" clamps from NAPA, that is where I got mine.

 

[JHerrlich]

I got mine off without cutting. I had to use a torch to heat the exhaust where the clamps were and I managed to wiggle the thing off. Incedentaly, I have a stock resonator and muffler in perfect condition w/the hangers still attached.

 

[Evan A. Beck]

Before you go and buy some more tools, you may want to try this...



To break the bolts loose, just try heating up the tabs on the turbo elbow with a torch. Heat it just on onse side though, preferable the outer side. Make sure it is glowing red hot just on the one edge. The bolts should com eout no problem because you expanded the cast iron with the heat.



As to removing the rest of the system, hack the hell out of it with a Sawzall. Spray some WD40 or PB on the rubber hanger parts, and then just use a prybar to slip the tapered rods out of the hangers. Loosening the clamps won't do much good, since the top and bottom of the pipe will be dented in pretty good from when it was assemebled at the factory.



Here's a tip for installing the new system... Be sure to put some anti-seize on the bolts connecting the downpipe to the turbo elbow. This will make it easy if and when you have to remove it again. Also, install the downpipe first, and just make the bolts snug at the turbo elbow. This will give it some play for when you are aligning the rest of the system.



Good luck!

 

[Archive]

I wouldn't hack the heck out of it unless you need to. We have done it with one cut... no hanger cuts. You never know when you or another BOMBer may need it!