3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

newbie shade tree????

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Old Dec 14, 2006 | 06:46 PM
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03whitedually's Avatar
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From: Virginia
newbie shade tree????

Ok guys I'm trying to put on my new exhaust and it is killing me. I've finally gotten all clamps loose and tried to start pulling off hangers and they didnt budge, pulled of metal keeper rings from hangers and sprayed with wd-40 any advice would be great. I really dont want to have to cut so if i have to take off this system for any reason, but i will .
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Old Dec 14, 2006 | 07:47 PM
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I just removed my exhaust a few days ago. First I cut out the muffler. Then I removed the tail-pipe section. Then after about 20 minutes, I was able to pull the remainder back and out. I had to rotate the pipe to get the down pipe section out. Mine is a six speed, so I don't if it will be the same for an auto (not sure how wide the auto). My hangers came off easy though. The re-install was a piece of cake. Just the reverse. Then I put in a new muffler. The reason I removed the whole section was becasue the crimps on the muffler I was putting in were way to tight. I needed to have the pipe and muffler out in order to straighten the bent sections.
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Old Dec 14, 2006 | 09:06 PM
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WD40, get all the pipe loose(or cut it enough to be able to manuever sections), and pry and pry and pry till it comes out
I was lucky with most of them coming right out, the last one I just WD40d up, and wiggled it little by little till it came out....
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Old Dec 14, 2006 | 09:39 PM
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From: Harford County MD
i used a cutting torch and made two small lines on opposit sides of the pipe that was pinched. then using an air chisel, i bent the muffler flaps up enough to slide the resonator out. i could install my muffler again if i needed to, but it would require a few tack welds. It didnt damage it too bad. if you're going to do this, be quick with your cutting torch, because before you know it, you're cutting through the resonator. Good Luck
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Old Dec 14, 2006 | 09:41 PM
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From: Ojai/Port Hueneme, CA
use a small diameter pipe or something similar and place one end on the rubber hanger, and beat the other end with a small sledge or mallet. Worked great for me, came right off!
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Old Dec 15, 2006 | 03:12 PM
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03whitedually's Avatar
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down pipe band clamp!!!!!!!!!!!!!!

I dont know who's idea this abomination was but they need to be drug into the street and beaten, i fought for 4 hours just trying to get that one clamp on, once that was on 30 minutes to finish. The best part is the drone is gone and it sounds great! THANKS FOR ALL THE IDEAS !!!
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Old Dec 15, 2006 | 03:15 PM
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I had problems with mine to, Had to cut it off...I love how so many of these products are advertised as 10-15 min installs, guess I'm just a lil slow.
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Old Dec 15, 2006 | 03:17 PM
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I've been watchin tv shows that say its so easy, from start to finish 7 hours for exaust and 2 hours for intake
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