First off, thanks to everyone who has done this in the past and posted up about it! 
I have some questions listed at the bottom. So if you don't want to read my little rant, feel free to scroll on down.
I went into this project well informed and was ready for anything to happen. Almost.
I had all of the parts assembled and ready to go, however, the magnesium chloride bulls*** that's used on the roads here in Colorado has corroded everything all to hell. 20 year old parts I can understand but the o2 sensor nuts, which are 5 years old, are almost gone. I had to cut out almost all of the exhaust to get it off the truck as all of the other fasteners were toast as well. I was able to get the front o2 sensor nuts off once off the truck with some vose grips. The rear nuts? That's another story. The shield is in the way so I'm going to try a nut extractor(fingers crossed).
My plan is(was?) to keep things mostly stock and replace what is necessary. That meant replacing the front pipe w/cat and muffler section, all gaskets and fasteners, while keeping cat 2 and the tail pipe. I got the front pipe from Magnaflow and went with the OEM muffler section. The OEM front pipe was just too expensive for me.
Well, it appears that I have to order more stuff. Sux. 3 of the 4 EM->front pipe studs came out with the nuts, and one of them has some jacked threads on the pipe end so I'll be replacing the three that came out. I don't want to touch the one that's still in there. With my luck, it'll break off, inducing a round of tourettes
that will wake the dead. I also need a rear hanger cushion as I didn't expect to have to remove the tail pipe at the end. The studs just twisted right out. Sux, x2. I had to cut off the band that holds the front pipe up by the manifold so that needs to be replaced. I've been looking for the part number for that but can only come up with the whole assembly. It looks like the resonator has developed a rust hole on the top of it so that will have to go as well. <===This project has got me beat down.
So, I have a few questions if anyone can help me out here:
1) How in the world does the tail pipe come off of the truck?!?! I have tried moving thing all around and the flange just gets jammed between the body and the frame crossmember. Does the truck have to be up on a lift? I can cut it out, but getting the new one in looks to be a serious challenge.
2) Has anyone had any luck using one of those nut extractors on the o2 nuts? Will I be wasting my time? I can try to cut off the nuts, but I don't want to lose the shield if I can help it. In that, does anyone have the PN for the shield? I can't find it on the online resource I know.
3) Is the band that holds the front pipe to the hanger available by itself, or is sold only as part of the hanger?
Thanks in advance for any answers, help, advise, razzing, etc. Any/all is much appreciated!
I have some questions listed at the bottom. So if you don't want to read my little rant, feel free to scroll on down.
I went into this project well informed and was ready for anything to happen. Almost.
I had all of the parts assembled and ready to go, however, the magnesium chloride bulls*** that's used on the roads here in Colorado has corroded everything all to hell. 20 year old parts I can understand but the o2 sensor nuts, which are 5 years old, are almost gone. I had to cut out almost all of the exhaust to get it off the truck as all of the other fasteners were toast as well. I was able to get the front o2 sensor nuts off once off the truck with some vose grips. The rear nuts? That's another story. The shield is in the way so I'm going to try a nut extractor(fingers crossed).My plan is(was?) to keep things mostly stock and replace what is necessary. That meant replacing the front pipe w/cat and muffler section, all gaskets and fasteners, while keeping cat 2 and the tail pipe. I got the front pipe from Magnaflow and went with the OEM muffler section. The OEM front pipe was just too expensive for me.
Well, it appears that I have to order more stuff. Sux. 3 of the 4 EM->front pipe studs came out with the nuts, and one of them has some jacked threads on the pipe end so I'll be replacing the three that came out. I don't want to touch the one that's still in there. With my luck, it'll break off, inducing a round of tourettes
that will wake the dead. I also need a rear hanger cushion as I didn't expect to have to remove the tail pipe at the end. The studs just twisted right out. Sux, x2. I had to cut off the band that holds the front pipe up by the manifold so that needs to be replaced. I've been looking for the part number for that but can only come up with the whole assembly. It looks like the resonator has developed a rust hole on the top of it so that will have to go as well. <===This project has got me beat down.So, I have a few questions if anyone can help me out here:
1) How in the world does the tail pipe come off of the truck?!?! I have tried moving thing all around and the flange just gets jammed between the body and the frame crossmember. Does the truck have to be up on a lift? I can cut it out, but getting the new one in looks to be a serious challenge.
2) Has anyone had any luck using one of those nut extractors on the o2 nuts? Will I be wasting my time? I can try to cut off the nuts, but I don't want to lose the shield if I can help it. In that, does anyone have the PN for the shield? I can't find it on the online resource I know.
3) Is the band that holds the front pipe to the hanger available by itself, or is sold only as part of the hanger?
Thanks in advance for any answers, help, advise, razzing, etc. Any/all is much appreciated!
