I am ready to remove the stock system from my 2002 Screw and install a new bolt on cat-back system. Can anyone please tell me the best and easiest technique to remove the hangers from the rubber bushings without doing any damage to both parts? (tools, technique) . Thanks

 

I've used a Saws-All and Angle Grinders. If you can't coax the nub away from the rubber, try cuttin' the other side at the bend and pull it through.

 

Put a little PB Blaster on the rubber and pry off with a prybar, It will slide off with a little pressure. ---Paul

 

I readily don't have a can of PB Blaster on me, but i do have a can of Liquid Wrench. I'm just wondering if the rubber is poreous enough to absorb the lubricant and ruin it (just as the common problem of swollen front end bushings and CV boots due to contamination) Great idea and I hope that works out. If all else fails, I'm just gonna hava to grind off the hanger nubs, as previously mentioned, to make thinks easier. Thanks for the replies.

 

Use half water half dish soap, apply with old paint brush. Pry off rubber grommet. If you don't want any residue try Windex in the can, great for installing hoses.

 

another great idea! Thanks...

 

Here's what I did, I took a bottle of hand soap and squirted it on the post near the nub. Just a few twists here and there and it slid right off.

 

Did this mod to my Supercrew, and the advise you're getting from everyone is right on. I used a 50/50 mix of Simple Green and water on the rubber hangers to lube them, but as others have suggested, there are a number of options. One suggestion though that hasn't been mentioned so far (I think anyway). If you can borrow a lift to get your truck up off the ground the job will go soooooooo much easier. I have a friend that works for a tire store, and he let me use one of their lifts a couple hours before closing on a slow day. With the lift, the whole swap took right at an hour to complete, and that working by myself. Expect to spend a lot more time on your back in the driveway if you don't use a lift. Good luck.

By the way, what catback did you get?

 

I'm getting the Gibson Supertruck. Can you give me a details, hints, tips, and instructions how you went removing the stock system? To me the hardest part of this project is removing the stock system. I hear that Ford has done a good job keeping the stock in place and it may be a challenge taking it off. I expect to receive my Cat-back this Wedensday and hopefully Saturday morning, I would start the project in my home garage. ...and no, I don't have access to any lift

1. How did you separate the head pipe from the muffler inlet? I know I may be required to cut, but can you give me a hint what the instructions say, or mybe there is a better technique?

2. Did you use a crow bar to pry apart the bushings from the hanger? or Channel lock? your own hands?

3. Did you have it welded after you clamped the system to ensure that there are no leaks?


thanks.. Mike

 

Mike,

I used a portable bandsaw to cut the stock pipe just before it went over the axle, so I had to parts to work with when taking out the stock system. You could use a sawzall or jig saw with a metal blade in it also.

On the stock handgers I used a angle grinder to cut off the hanger just above the pipe, so when it dropped I just pulled the pipe out. I only tried for about 3 min to get it out in one piece and quickly gave up, cut it in half and out it came.

I used a sawzall with an 11" metal blade to cut the pipe between the muffler and the cat, right at the face of the Muffler, then heated it with a torch to take off the belled muffler pipe that was left on the pipe to the cat.

Using soap to lube the rubber hangers worked great when putting the stock system back in.

I only had it on for ~ 19 months or so, but the clamps were all I had on it, I never bothered welding it together.

Good luck putting in the system.

Steve

edit : change the 'face of the cat', to be what it should be, 'face of the muffler'..opps that was wrong

 

Ok, these tips are based upon my having used a lift to install mine. By the way, SSCULLY's tips are right on if you do your install without a lift. Here goes.

1) Spray the rubber hangers with whatever you're going to use, and let them set for maybe 10 or 15 minutes to soak in. At the same time, hit the flange bolts (connection between the muffler head pipe and Y-pipe collector) with some thread lube. I only found a need to do 'one' cut to the head pipe (with a chain pipe cutter) about a foot rear of the flange. That gave me enough play to wiggle the whole system out in one piece (i.e. I made no other cuts in the system or ground off any hangers). I sold that stock system to a guy here locally because he'd only have to weld in a single pipe connector to re-use it on a truck he owned.

2) I used a large pair of channel locks to pull apart the hangers. Really, if your spray on lube does it's thing properly, they come apart pretty easy.

3) I clamped mine on but have since considered having it welded. Guess I just wanted to make sure the system I bought (Magnaflow) turned out to be right for me.

That's about it. Hopefully you won't have too difficult a time getting it on your truck. Good luck with your install.

 

I had my supertruck welded only because the clamp did not hold. And yes, the stock system is very difficult to remove. Even with my 3 ton jack which has an 18" or more lift on it, I had a major time getting it out.

 

Man... I love this forum! Guys, thanks for all great info. I'll let you know how it goes (if I can get it on).

 

First thing I did was to soap the hangers. I then jacked the rear of the truck up about 1 foot. I used a sawzall to cut the headpipe and that allowed me to wiggle/slide the WHOLE system right off. The soap that I used was slippery enough to allowed me to just slide the rubber grommets right off the hangers by hand.

 

Another wonderful use for KY!