DT Cat-back Install

[FlammableFishie]

Guys, I got in over my head.

So I'm trying (failing) to install my DT cat-back exhaust on my 100 series. I've managed to get all 6 stock bolts off of the exhaust, as well as pull part of the muffler off. My current issue is with the parts of the exhaust that hold it up to the truck. I can't seem to detach these:

I've tried everything I can think of. I've used soap and water to lubricate them, I've tried a screwdriver to pry them off, I've even used a sawzall to cut off two of those points on the muffler. I decided to give up on the sawzall for one of the points because it wouldn't cut as the pipe moved around too much. But I really need input on how to get the stock pipes off and any advice on how I should put on the DT exhaust the easiest.

I'm ready to give up and I need help. Thanks guys.

 

[SupraTuRD]

Spray PB Blaster from both sides and use a pry bar to force the rubber grommets off of the posts.

 

[FlammableFishie]

Spray PB Blaster from both sides and use a pry bar to force the rubber grommets off of the posts.

Definitely gonna try this in the morning, will report back on how it goes. Never expected to spend so long taking out the OEM exhaust... what a pain.

 

[SupraTuRD]

Be advised the OEM muffler weighs a ton... don't let it fall on you.

 

[Redcrayon]

I used a saws all to cut the little fat tip off of the part going through the rubber. Was able to slip it off fairly easily then.

 

[petrotk40]

remove it from the upper mount, don't try to get the lower one out while on the truck.

 

[FlammableFishie]

SupraTuRD, you are my hero. A few squirts of PB blaser on the frame mounts and I was able to pull off the rubber hangers easily. Luckily one of my buddies stopped by right after I took off the OEM muffler (doesn't weigh THAT much, I let it fall on my chest) and he was able to help me place and mount the rest of the DT system. Super super happy with the results, but I need to go back under and retighten the clamps because there is a little rattle from one of them. Hopefully it'll be an easy few turns without any surprises, but who knows... Overall, this was worth saving the $100+ that I was quoted for an install. Just wish I had used the PB Blaster as lube earlier, would've saved me a lot a sawing and frustration!

 

[FlammableFishie]

If there are a few tips I can give, since I couldn't find any with a quick search, it's to:

PB BLAST ALL THE BOLTS at least a few days before you install, at least once if not more.

USE PB BLASTER AS LUBE for all the hangers and remove the hangers from the frame first, then use some more PB Blaster to lube up the connection point on the exhaust, then simply put the rubber hanger on the new exhaust to mount on the frame.

PUT THE MUFFLER ON FIRST then you can put on all the other pieces. This isn't how I did it though, I put everything but the muffler on first and found that was slightly more challenging than if we just put the muffler on first. And finally,

LEVERAGE IS YOUR FRIEND. A simple 6in ratchet won't get off 13yo bolts, you'll need something a bit heavier duty than that. I improvised and cut a pipe to fit over my ratchet for more leverage. It was ghetto, but it worked!

Good luck with your install, and trust me, it's worth doing it yourself in the end.

 

[SupraTuRD]

Glad it worked for you! What are your thoughts on the drone that occurs at 2k rpm?

 

[FlammableFishie]

Glad it worked for you! What are your thoughts on the drone that occurs at 2k rpm?

It's nothing that bothers me too bad, it just sounds like that is where the pipes resonate with the wave frequency of the exhaust. Thankfully highway driving is just above 2k rpm though, otherwise that would be pretty loud!