Dual Exhaust System Removal
So, out comes the exhaust system. I removed the clutch Z-bar assembly in the engine bay to get at the left manifold bolts, but no luck. So I broke out my trusty Sawzall and cut the pipes. Even this is tricky as the saw was very awkward to get into position. And yes, I know it would have been easier to pull the rear axle first. This is, after all, my first rodeo.
Here's a shot of the rear end before the hammer (and Sawzall) came down:
There are hangers at the end of the floor pan that have to come out. I don't have a good shot of the hangers in place - it's a tight area to get into - so I'll just show you what it looked like after it's all out.
Drivers side - the two small holes are where the lag screws were holding the hanger. The big hole is where I removed the rear seat belt and found it was held in place by a few fender washers between the bracket and the floor. Yikes! It's a mess, no doubt, and there is some real metal work to be done here to get it back into shape.
And the passenger side - not a lot better. The holes on the right were where the hanger was connected - the large hole is for one of the seat belt brackets. Notice the cracks in the floor (called the shock mounting reinforcement panel) and a bunch of screws that should not be there. Greasy, oily, spider-webbed, cracked and generally gross. Just another mess to fix.
There are also hangers at the end of the rear frame rails that come out. I just cut the rubber section on each one so I could control when it dropped out.
And that's about it. The system is really only held in at three locations - the exhaust manifolds, the rear floor pans and the rear frame rails. If the rear axle had been out I could have slide the entire thing out in one piece. Instead, I had to cut each set of pipes at the muffler and weasel each section out in pieces. This is fine is you're not keeping any of the old system.
The mistake I made here was getting in a hurry to recycle all this without cutting the exhaust tips off - they could have been reused, and that's an $80 mistake right there, and why I added the 'keep all old parts' commandment back in my earlier post.