I'm beginning the process of rebuilding my front and rear suspension and already I've hit a snag. I've got the complete exhaust system disconnected at all points (even pulled the exh. manifolds and all the heat shields) and all clamps loosened, but I can't seem to separate the middle and rear mufflers from the front cat pipes. First, can anyone give me some tips on how to separate the pipes without damaging them, as nothing is worn out and I'd like to re-use everything. Secondly, can the complete exhaust system be removed as a unit with the car up on jacks? The main problem seems to be that the front pipes with the cats don't clear the idler arm mount. Is it possible to wiggle or twist things enough to get it to drop past this point? I was working on it by myself today, but I plan to go back with another set of hands in a day or two.

I'd appreciate any help or advice.

Thanks,

Gary

Hi Gary
I would not separate them but remove the whole exhaust as a unit. This was not a big problem with my 92 300TE - I guess yours must be similar. First I first removed the four bolts that attach the downpipes to the exhaust manifold, removed the oxygen sensor, the rubber hanger there and the ones at the center muffler. Then I wiggled the exhaust back and forth till the downpipes dropped from the enginge bay. I then released the rubber hangers of the rear muffler (I supported it with a floor jack to make it easier). The whole unit can then be pulled from the car.
Good luck, Bruno

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1992 300TE 160 kmiles

Bruno is correct and your 86 is the same. Don't even consider separating the exhaust systme components. Drop the whole thing as a unit. You will have to move the rear around quite a bit in order to get the flanges to clear.

Depending on what I'm doing I usually don't completely remove it. I simply disconnect everything and let it down and move it side to side to get it out of the way. This will depend on whether you are working on the shop floor with jacks or on a lift. On a lift, I have used a transmission jack to get it out, but it is a bit precarious and would best be done with a helper AND the trans jack.

Good luck,

remove as a unit...

I once had to separate.... couldn't do it with a propane torch...needed much hotter acetylene. Took it to a high school weld shop to have it done.....

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1989 300ce 129k
( facelifted front,updated tail lights, lowered suspension,bilstein sports, lorinser front spoiler, MOMO steering wheel, remus exhaust,stainless steel brake lines). (Gone)

1997 s320 154k (what a ride). Sold with 179k miles. Replaced with Hyundai Equus

1994 e320 Cabriolet 108k



1972 280se 4.5 153k Owned for 12 yrs, sorry I sold it


[/SIGPIC]

Just to clarify, I've attached a picture of what I'm talking about. Should I be able to move the whole exhaust assembly toward the rear and clear the idler arm? It seems there's only about 1 1/2 to 2 in. before the rearmost pipe hits the lower bulkhead. If you say it can be done, I'll get in there with my son and do it. I figured splitting the front and rear sections would give me a little more manipulation room, but I'd rather not separate them if I don't have to.

Thanks,

Gary

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The 92 300TE does not have precats on the downpipes, I do not know how much of a problem they are. Otherwise it looks the same. On my car I manage to remove the whole exhaust in five minutes (that's after the fourth time I did it).
Good luck, Bruno

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1992 300TE 160 kmiles