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Rakthi



Member Since: 30 Nov 2012
Location: Where the cats are
Posts: 200
2011 Defender 110 Puma 2.4 HCPU Stornoway Grey
Exhaust removal - cross member stuck ... Question
So wife out for luncheon date with friends and a free afternoon, perfect time to bolt the Alive exhaust and de-cat to the truck.

Unbolted the chassis cross member and lo and behold, after almost one hour of pulling, pushing, beating with dead weight hammer, levering with 2x4 etc etc, the bloody thing hasn't budged a nanometer ... Evil or Very Mad Really wonder what is holding it in place.

Side note - according to service manual the bolts holding the cross member should be torqued to 85 Nm ... no way the ones on my truck were that tight. Came of easy peasy without too much force.

So guess I am now down to plan B ... cutting the down pipe of the cat. (might as well as nobody in Malaysia would want it)

So my question:

If I cut the pipe, can I remover the cat through the top or do I still have to go through the bottom?

Off to the store to get a hack saw ... Whistle
Post #252329 19th Jul 2013 7:05am
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william8



Member Since: 03 Apr 2013
Location: Motherwell
Posts: 259
Scotland 2008 Defender 90 Puma 2.4 XS CSW Zambezi Silver
Did you try putting a jack between the chassis rails? Always worked for me.

Cheers, William
Post #252336 19th Jul 2013 7:18am
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K9F



Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610
United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
Fekete cut his to remove it drop him a 'pm.' I believe it still heads downwards for removal but the crossmember can remain in place from memory.

Maybe nobody in Malaysia would want it but I received a handsome price from a forum member in another country where the rules are stricter. May be worth the extra effort to keep it intact, you may also wish to change the truck and retain the exhaust perhaps later? If you go through life with your head in the sand....all people will see is an ar5e!!

Treat every day as if it is your last....one day you will be right!!
Post #252342 19th Jul 2013 7:39am
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Rakthi



Member Since: 30 Nov 2012
Location: Where the cats are
Posts: 200
2011 Defender 110 Puma 2.4 HCPU Stornoway Grey
Didn't think about that due to the fact I do not have a jack long enough to exert pressure on the chassis rails.

Mhmm ... come to think of it the jack that came with the truck and a couple of blocks of wood might do the trick. Razz

Will be for another day though. Worn out for now.
Post #252345 19th Jul 2013 7:50am
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william8



Member Since: 03 Apr 2013
Location: Motherwell
Posts: 259
Scotland 2008 Defender 90 Puma 2.4 XS CSW Zambezi Silver
Come on....

Its only 9am here Laughing William
Post #252348 19th Jul 2013 7:57am
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Rakthi



Member Since: 30 Nov 2012
Location: Where the cats are
Posts: 200
2011 Defender 110 Puma 2.4 HCPU Stornoway Grey
william8 wrote:
Come on....

Its only 9am here Laughing


Oi, we are 7 hours ahead here! .. 16.25 where I am ... Will have another go at it tomorrow. But seems I will need lots of bits of wood Confused Whistle

K9F wrote:
Fekete cut his to remove it drop him a 'pm.' I believe it still heads downwards for removal but the crossmember can remain in place from memory.

Maybe nobody in Malaysia would want it but I received a handsome price from a forum member in another country where the rules are stricter. May be worth the extra effort to keep it intact, you may also wish to change the truck and retain the exhaust perhaps later?


Thanks K9F, yup you are right, I just might change the truck for a 7 seater in the future ... will give it another go and see what happens. Can always have the bleeding thing welded back together. They're amazingly good at those sort of things here.
Post #252359 19th Jul 2013 8:31am
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ken



Member Since: 18 Aug 2009
Location: Banging Birds with my bitches !!
Posts: 4328
United Kingdom 
Have cut on the 90 & 110 to fit SE Twisted on a 110 & Alive 3" on the 90Td5 Thumbs Up
Post #252378 19th Jul 2013 9:17am
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diesel_jim



Member Since: 13 Oct 2008
Location: hiding
Posts: 6098
United Kingdom 2006 Defender 110 Td5 SW Epsom Green
When i've removed my crossmember sometimes i've had to beat the thing out.

Usually try and get a hi-lift in there to open the chassis rails up a bit.

You only need a layer of rust in between the crossmember and chassis, and it'll be stuck as a stuck thing.
Post #252399 19th Jul 2013 11:36am
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Rakthi



Member Since: 30 Nov 2012
Location: Where the cats are
Posts: 200
2011 Defender 110 Puma 2.4 HCPU Stornoway Grey
Ended up cutting the exhaust. Not having a hi-lift, tried spreading the frame using a strong piece of wood and the scissor jack from my wife's Picanto, but no joy ... Didn't budge. Contemplated putting a strap around the cross beam and drive the car backwards to pull it off, but thought that would be a bit over the top (and who knows where the cross beam would have ended up ).

Looks like when they assembled the truck here in Malaysia, they slathered some tar-like substance on the frame before bolting in the cross beam. This effectively glued the 2 bits together.

Anyways ... old exhaust is out and the new one is in.


Click image to enlarge

And FYI, the EU2 exhaust does have a cat in there. Supposedly less restrictive than the EU4.

Haven't had the time yet to try the new set up. Even after cutting the downpipe, it took much longer than expected to get the old exhaust out of there. Installing the new one was easy peasy. 30 - 45 minutes tops including re-installing front drive shaft and rear mudflap.
Post #252712 21st Jul 2013 12:21am
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diesel_jim



Member Since: 13 Oct 2008
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Posts: 6098
United Kingdom 2006 Defender 110 Td5 SW Epsom Green
What does it sound like now?
Post #252716 21st Jul 2013 5:36am
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Rakthi



Member Since: 30 Nov 2012
Location: Where the cats are
Posts: 200
2011 Defender 110 Puma 2.4 HCPU Stornoway Grey
Just back from a 20 KM drive to make sure nothing fell off.

Very pleased with the sound ... although only hear it at tick-over.

Not much louder, but more of a nice bas warble to it. Very Happy Thumbs Up

In the cab no difference at all, maybe a tad louder at high RPMs.

As for the rest ... cooler in cabin (no hot footwell) and - purely subjective - quicker pick up of the revs and a bit faster pulling from stop.

All in all, very pleased indeed.

Now saving up for an intercooler. - According to the UltraGauge my intake temp dropped from 42 - 45°C to 38 - 42°C when at operating temp. This with 32°C temps outside. This will have to be confirmed over longer distances then 20 KM though.
Post #252718 21st Jul 2013 6:08am
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