I've read a fair amount about this but haven't found anybody who has explicitly said they succeeded in removing the oil sump in an '02 D2 without removing the frame cross member. Has anybody succeeded in doing so? I'd also like to avoid pulling tie rod as I just had it aligned.

As usual, the cross member is hopelessly seized to the frame. I've been soaking it in PB, tapping and prying for about 2 weeks now and can't get the bloody thing off. I've sripped one of the 8 bolts and partially stripped 4 more. I have 3 loose.

Thanks!

 

Takes a BFH sometimes to get cross member down. Have you tried a high lift jack and jacked the frame open?

 

I've been using a 4lb sledge. I don't have a high-lift (always wanted one) but jacking the frame apart seems a bit forceful to me. I'd be afraid of permanent deformation.

 

Don't worry about deformation, that's how all d1/d90/rrc V8 crossmembers are removed, porta-power hydraulic separator

 

1st try heating the bolts with a torch. If not successful get you some Kroil!
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Last option is to dremel the heads off to get the x-member out, then drill the old bolts. You might be able to use a bit small enough to save the threads, or you may need to drill a larger hole and retap.

BTW, there's at least one dude who just left that crossmember off, and had no problems (yet).

 

There is a cult of several of us

 

Maybe your that Dude? You back to work yet?

 

I'm always at work!

 

unbolt the pan, jack the body up and you will have room to take the pan down, with the member in place. at least i did