Cat removal and replacement

[JeffW]

I have a 3" THDP w/ a 3" high flow cat currently on my 87. I am in the process of replacing the cat with a "higer flowing unit" . I'm also running a hooker dual 2.5" with the exhaust flange welded to the hooker.

I have managed to remove all four bolts from the cat flange and a clamp where the cat overlaps the DP. I've sprayed some rust remover to loosen the cat/DP overlap, and it's starting to loosen up to where I can rotate the cat.

How do you get the cat flange to clear the exhaust flange ? I can't seem to pull the exhaust down enough to allow the cat flange to get behind it. Do I need to remove the DP. That would seem to remove all my leverage to pound that cat off the DP. Is there some sort of hanger I didn't see that hold the exhaust side flange up ?

Thanks for the help

 

[JeffW]

TTT

Can anyone help please ?

Thanks !

 

[salvageV6]

First time with rusty stuck bolts I would loosen everything like you have it then take the dp off the turbo and drop the cat. which of course still won't come off the downpipe easily.

At least from there with two people you should be able to orient it to band the cat off the thing.

Pain in the butt but that's how I had to do it.

 

[turbofrank]

Remove downpipe from elbow now pipe and cat are laying on ground. Push pipe as far as possible up front. Hold the back of cat
with foot or hand use a no bounce hammer to hit the pipe forward
while pushing cat back.

If that don't work take a hacksaw and cut the downpipe from cat you can always take the downpipe to a muffler shop to have a end piece weld on.

 

[ponch]

I just removed mine and here is what I did, I cut one small slice on each side of the pipe using a dremel tool that allowed the cat to slide off the DP. Just watch how deep you cut the slice so it doesn't cut into the DP. HTH

 

[JeffW]

Well I ended up taking it to a local "friendly" muffler shop. They simply cut off the cat and bolted in the "higher flowing unit". They did use some exhaust sealant on the flange. Already got it tuned in. Had to turn the wastegate rod out 4 turns to get it back around 21-22psi (alky).

Thanks to everyone for the great advice. That was very tough trying to do on my own.