Tom:

The exhaust header has probably been dented in by the clamp. If you can find an exhaust pipe expander (cute little thing that has steel sections that expand outwards when you tighten a bolt in the center), stick it in there and re-expand the pipe.

This may and may not get the pipe free enough to remove -- I usually just get a hacksaw blade holder out (the little on that leaves one end of the blade free) and slot the pipe so I can collapse it and get it out without ripping the muffler pipe up.

I hate exhaust work (which is why I still have a split header on the 280 SE 4.5). How bad is getting the left manifold off?

The only way the flap can get completely stuck is if there is a mouse nest in there -- sounds like more fishing, or worse, heater box removal. The valves will be easier with the heater core out......

Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!