Need help removing HDJ80 factory exhaust (1 Viewer)

[HRTROB]

Hey guys I’m trying to install an exhaust system on my HDJ80. Ran into a couple of problems. First, one of the 14mm bolts holding the down pipe bracket to the engine won’t come off. It’s pretty tight so there is now way to use a socket wrench. I’ve already used a flare nut wrench, still won’t budge - the bolt just deformed. I also tried two kinds of vice grips, still won’t budge.
Second problem is I can’t find a way to remove the tail section. I can’t figure out how to “unhook” it from the chassis crossmember. The flange is getting caught up on the crossmember. Any trick to getting it out?

 

[ZCissner]

your trying to remove the old one?
cut it off.
i just did this on mine and i cut it

 

[HRTROB]

your trying to remove the old one?
cut it off.
i just did this on mine and i cut it

Yes I’m removing the factory exhaust. I’d prefer not to cut it if possible.

Already got the dump pipe off and the new one in. I had to bend the bracket since the stubborn bolt wouldn’t come off. All that’s left to do is get the flange over the corossmember so I can pull the tail section out

 

[ZCissner]

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• ZCissner
• Jun 4, 2020

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• ZCissner
• Jun 4, 2020

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• ZCissner
• Jun 4, 2020

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• ZCissner
• Jun 4, 2020

I did my down pipe inside the frame, straight back and up and Over the axle and out the side

 

[ZCissner]

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• ZCissner
• Jun 4, 2020

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• ZCissner
• Jun 4, 2020

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• ZCissner
• Jun 4, 2020

I put 3 v-band clamps in so it comes out in 3 pieces (except the down tube) and takes about 3 minutes to pull it off

 

[Feistl]

Hey mate, looks good but if I can offer some advice...

Make up some sort of bracket between the gearbox/bellhousing and the exhaust to give it more support.

You have a lot of weight hanging off the turbo in the current setup which really isn’t ideal. Plus if your exhaust hits something (if you take it off-road) you could easily damage the turbo housing.

It’s also a bit hard to tell in that picture, but it looks like an upgraded turbo?? If so, does it have a support bracket in place? I made a bracket to support BOTH bolt holes although even one is better than nothing.

Other than that it looks good and should give good results.

 

[ZCissner]

There is a turbo bracket from the turbo to the block, and then a exhaust mount about 2.5 feet from that, god I hope I don’t hit it on anything, it’s about 2 inches higher than the t-case

 

[HRTROB]

Okay I got the tail section out at this angle. I sprayed WD40 on the pipe and crossmember to reduce friction then pulled hard while twisting and wiggling at the same time.

Then for the new pipe section, I had to get it over the crossmember from the front side. I got it over from the rear but the rest of the pipe was pointing downwardsand no way to get it over the axle