HELP! 2004 Sahara - Removing Exhaust DP - Jeep Wrangler Forum

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Old 02-02-2013, 10:41 AM   #1
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HELP! 2004 Sahara - Removing Exhaust DP

Help! I'm getting ready to repair the rear main seal leak and I'm at a loss. I'm going through this write up and the DP on mine looks custom. The DP goes 2 to 1 from the header to the cat in one piece. There's very little space to get to the bolts at the header and it looks like I will have to remove the skid plate to disconnect at the cat.

Could I just unbolt at the header and let it hang (assuming I can get those bolts off)?

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Old 02-02-2013, 10:52 AM   #2
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Location: San Diego
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Just did mine last night. Very difficult to get the bolts off my '02, but sprayed them down with Liquid Wrench and then was able to get a 15mm socket on the bolts and get them removed. It is a tight spot, but something that worked for me was to slip the socket on the bolt, and then attach the ratchet and extensions to the socket. Sounds convoluted, and it is, but it worked. Appears to be the most difficult part of the job, but I need to complete the RMS replacement, so time will tell. Good luck!

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Old 02-02-2013, 10:59 AM   #3
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i did spray the bolts down last night with pb blaster. looks like i'll have to bust my knuckles to get to that sob. did you just leave the dp hang with the exhaust hangers and move it around?
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Old 02-02-2013, 06:49 PM   #4
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I took mine all the way off. Only way I was able to get the pan removed.
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