[DMCForum] Re: Worst Case Scenario: The DeLorean Edition

["cruznmd" <racuti1@xxxxxxxxxxxx>]

Yes indeedy. I just did all this. The crossover pipe studs were the 
worst. They fused into my exhaust manifolds so bad, I had to 
drill 'em out. I screwed that up (my aim wasn't true) so I ordered 
some from Darryl Tinnerstet and they shall be here today!

I'm doing this in my driveway too. At least it's dry now.

--- In DMCForum@xxxxxxxxxxxxxxx, Travis Goodwin <tgoodwin@xxxx> wrote:
> Try not to have a heart attack when you read this stuff!
> 
> http://tg2.vantagep.com/Worst_Case_Scenario.pdf
> 
> This file is 426K because I took lots and lots of pictures, as 
promised.
> Enclosed below is just the text:
> 
> ----------------------------------------------
> 
> 
> Worst Case Scenario:
> DeLorean Exhaust Gaskets
> 
> First off, I gotta give mad props to Martin Gutkowski (whose 
original
> document got me brave enough to try this madcap procedure) and all 
the boys
> at DMCForum. 
> 
> If you ever ask anyone about doing this procedure, 9 out of 10 will 
say,
> "Leave it to a professional." Sage advice, but I'm too stupid to 
listen. For
> all of you who want to give this a shot, I've documented everything 
I went
> through in hopes of building a better understanding.
> 
> Step 1: Assessing the Project
> 
> Before I started anything, I crawled under the car to get an idea 
of what I
> was going to have to do to remove the manifolds. I took lots of 
pictures
> just to make sure.
> 
> This is the left side.
> 
> This is the right side. 
> 
> Now that I had a good idea, I went on to...
> 
> Step 2: Loosening the Muffler
> 
> There are 2 lower mounting brackets along the bottom of the muffler 
and a
> rubber bushing at the top near the coolant tank.
> 
> Remove the bolts holding this bracket to the engine.
> 
> In this picture, I have already removed the bolts securing the 
bracket to
> the engine. While you're under here, take some time to clean up. My 
engine
> is mighty dirty from the last oil change! 
> 
> After I unbolted it from the engine, I realized that if I unbolted 
it from
> the muffler, I would have enough swing to remove the muffler before
> disconnecting the cat. Otherwise, if you choose to leave it 
attached, you
> will have to wait until the cat is free to remove the muffler.
>  
> 
> Remove the 2 bolts above and below the rubber bushing and pull it 
free. The
> muffler should now be loose, but still connected firmly to the cat.
>  
> WORST CASE SCENARIO 1: BROKEN MUFFLER HEAT SHIELD
> 
> At this point, my weakened muffler heat shield broke. The stress of 
the
> dangling muffler was just too much. Because of this, I was able to 
swing the
> brackets down and free it from the cat. Cost of mistake: $75 (for 
new,
> improved PJ Grady heat shield)
> 
> Step 3: Disconnecting the Crossover Pipe
> 
> The crossover pipe is so named because it crosses over the top of 
the
> transmission and connects the two exhaust manifolds to the cat. 
> 
> In order to gain proper access, I had to remove the drive axle from 
the
> transmission. This step is not necessary but I got tired of 
fighting with
> it. It's a simple procedure involving 6 bolts. Just remove them and 
the axle
> will dangle out of the way.
> 
> Next, I removed the oxygen sensor. You need it out of there to 
access one of
> the bolts and to keep it from being damaged. Before you unscrew it, 
follow
> the wire that connects to it through the wall and into the wheel 
well.
> Disconnect it from there. Now you can remove it.
>  
> WORST CASE SCENARIO 2: SHEARING BOLTS
> 
> Now that I had easy access to everything, I joyfully went to 
removing the
> first bolt. It was tight, so I tapped on it with a hammer. Then I 
thought
> I'd try some penetrating oil. Soon the bolt began to turn. SNAP! 
The head
> falls out and onto my chest. I take a good look at it and see the 
culprit.
> The nut had rusted and actually fused itself to the bolt. No amount 
of heat
> or oil would save it.
> 
> After 2 more broke just like the first, I resigned myself to the 
fact that
> this was not going to work out like I had planned. So, out came the 
Dremel.
> I cut out all 6 nuts off the left side and went ahead and cut the 
two off
> the right side.
> 
> Whether you cut them out or you were lucky enough to get them to 
unbolt, the
> crossover pipe would be free. If you haven't removed the muffler 
already,
> you will have enough wiggle room to get it off now.
> 
> Step 4: Removing the Catalytic Converter
> 
> Normally, this would be easy (that is, if you got everything to 
unbolt) but
> mine was so rusted that it was frozen in place. I tried drilling it 
out but
> I couldn't get enough leverage. So, I gave up for the time being 
and moved
> on to...
> 
> Step 5: Removing the Manifold
> 
> With the muffler off and the crossover pipe loose, I had enough 
room to get
> the manifold off without removing the cat. Now that I know this, I 
suppose I
> could have just left it alone, but there is a gasket in there and 
if you
> want to replace it, the cat has to come off. 
> 
> By pushing the cat and crossover pipe as far back as it would go, I 
had easy
> assess to the left side manifold. Earlier in I had started spraying 
the nuts
> with penetrating oil. I kept them wet for 4 days before staring this
> procedure. Here's my results: 
> 
>  2 came off fine, 3 broke off, and one stud extracted with the nut 
fused to
> it. Could it have been worse. Hell, I suppose all of them could 
have broken!
> 
> Step 4 Revisited: Removing the Catalytic Converter
> 
> WORST CASE SCENARIO 3: STUCK CAT
> 
> I decided that the cat had to come out. I needed the crossover pipe 
to redo
> the manifold mounts and the cat had to be off in order to get the 
pipe out.
> After much deliberation, I came to the following possibilities:
> 
> 1.      Drop the transmission
> 2.      Cut the crossover pipe and buy a new one
> 3.      Cut the crossover pipe and have it re-welded
> 4.      Cut the catalytic converter
> 
> I finally decided on step 4. This left me with the most amount of 
options
> (wink wink) and the smallest financial penalty. Cost of mistake: 
$100-275
> 
> To prepare for the delicate removal, I took out the cat heat 
shield. It's
> held to the engine with 2 bolts. They come out very easily. 
> 
> Finally, the reciprocating saw made its first appearance with a 
fresh new
> blade. I pulled the crossover and cat as far forward as I could get 
it and
> cut the cat as close to the back flange as I could get it. The 
vibration
> shredded the honeycomb inside and now it sounds like a freakin' 
maraca.
> 
> The carnage:
>  
> And this was only the left side!

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