Long story short I had to replace my CATs and instead of the expensive manifold back I had some welded in. I still have a P171 code, which we have been chasing from the start. My Indy shop said there is still a leak somewhere and there is no way my muffler shop properly welded in a cat considering where they are without dropping the exhaust system.

So now that I am stuck between the two, I am dropping the exhaust to see if I can find a leak to get rid of the code.

I noticed there is a cross member that has what seems to be a support connection for the transmission. Can that be removed without supporting the transmission.

Are there any other gotchas to removing the exhaust system?

 

Yes it can, I dropped mine when replacing some corroded brake lines and did not need to support the tranny. I can not think of anything crazy about removing it though. The rear hangers were a bit of a pain but that was it. It was pretty straight forward. I did it alone while the rig was on stands in my gravel drive way. I did use a big piece of cardboard to lay on then drag it out on after it was out. If I think of anything else i will post it.

 

Did you ever check the far end, behind the engine, EGR valve connection? Its known to come apart a little and cause a leak. Easy to check/tighten from above if I recall.

 

I think we checked that, but will check again.

Already broke both bolts to the manifold on the passenger side. URGH!

 

I am about to set fire to this LR3. 1 bolt on the cross member does not want to let go I've already f'ed up the frame mount for it (Not sure how I am going to fix it) cutting off the head of the bold. Just crazy rusted in. I am about to just cut out the cross member and buy a used one if I can find one.

 

This thing?

https://www.ebay.com/itm/114633494795

 

The first pic is the bolt adjacent to the bolt that is stuck. That was a two day job to get out. Look at all the rust.

The second pic was me taking a grinder to the other bolt to cut the head off. You can see I took a lot of meat around the bolt hole on the bracket. How do I fix that or do I cut out the bracket and weld another in?

Do I just cut out the cross member at this point and jut get a new one?

URGH!!! This is worse than any job I have done on my D2's

 

Yep, that's the bastard!!!