This is the bracket that is welded to the pipe attached to the turbo. This bracket is bolted to another bracket that is bolted to the engine block. From below I can see where it has broken loose and can feel the seperation when I put my finger on the crack and hit the down pipe with my hand.

Is it possible to tack-weld it and then remove the pipe to properly reweld it or is it better to replace the pipe?

Is this pipe hard to remove from the turbo or is it a job for the dealer. I'm 67 and not sure I'm limber enough to be climbing into the engine compartment.

Is this a good time to consider upgrading the exhaust system?

I discovered the problem about 2k miles ago when a strange rattle/vibration appeared between 800 and 900 rpm. The sound is not particularly bothersome but we are about to leave on a 4 month 10k + mile trip to Alaska and I'm a little leary about the effect the pipe's lack of attachment to the engine might have on the turbo.

remove your splash shield and zap it did mine 2 years ago no removen the pipe or bracket the gap was only 1/4" or more no problns

Is it related to this?

Exhaust System - Rattle/Vibration

Bulletin No.: 03-06-05-007
Date: July 22, 2003
TECHNICAL
Subject:
Exhaust Rattle Noise or Vibration (Replace Turbocharger Exhaust Outlet Bracket)

Models:
2001-2003 Chevrolet Silverado
2001-2003 GMC Sierra
With the 6.6L Duramax(R) Diesel Engine (VIN1 - RPO LB7)

Condition
Some customers may comment on a rattle noise or vibration coming from the engine compartment under various conditions. The effected vehicles include:
^California emissions (RPO NB6) - All 2001 vehicles
^Federal emissions (RPO NF2) - 2001-2003 vehicles built before approximately 11/01/2002.

Cause
The turbocharger exhaust outlet bracket may break, allowing excessive movement and causing a rattle noise or vibration. Vehicles built after those listed will already have the updated bracket design.
Correction
Inspect for a broken turbocharger exhaust outlet bracket.
http://www.alldatadiy.com/alldata/AFI~V9090601~C36333~R0~OB0~P3R0H~N/0/86372027/87577297/87577392/87577396/34853741/100411974/34856670/34857012/42064152/121090653/102918806/102918807
If the bracket is broken from the turbocharger exhaust outlet, remove the right exhaust pipe (http://www.alldatadiy.com/alldata/AFI~V9090601~C36333~R0~OD~N/0/86372027/87577297/87577392/87577396/34853741/100411974/34856670/34856803) (1) and install the updated brackets to the turbocharger exhaust outlet (2). The first turbocharger exhaust pipe bracket (3) bolts to the right exhaust manifold (http://www.alldatadiy.com/alldata/AFI~V9090601~C36333~R0~OD~N/0/86372027/87577297/87577392/87577396/34853741/100411974/34856670/34856714), replacing the existing bracket. The second turbocharger exhaust pipe bracket (4) clamps around the turbocharger exhaust outlet (2) and bolts to the manifold side bracket (3). The bracket bolt (5) may have to be temporarily installed without the washer to engage the threads enough to initially compress the bracket and then reinstalled with the washer.
http://www.alldatadiy.com/alldata/AFI~V9090601~C36333~R0~OB0~P3R0H~N/0/86372027/87577297/87577392/87577396/34853741/100411974/34856670/34857012/42064152/121090653/102918806/102918808
Parts Information
Parts are currently available from GMSPO.
Warranty Information
http://www.alldatadiy.com/alldata/AFI~V9090601~C36333~R0~OB0~P3R0H~N/0/86372027/87577297/87577392/87577396/34853741/100411974/34856670/34857012/42064152/121090653/102918806/102918809

JEFFROO and 02GMCDMAX, thankyou for the replies. The TSB appears to cover my problem. Looks like the quickest and least expensive fix will be to pop the fender liner out and take to the local exhaust system shop to have it welded.

I suppose if my truck had a catalytic converter the replacement might be covered under the 5yr 100k emissions warranty.

I have a factory turbo down pipe if you need it. I went with a BD unit . The bracket that goes to the pasenger side of the block is not welded on the down pipe. It can be replaced if needed.

C.A.P, my turbo down pipe has a bracket welded to the pipe which is bolted to another bracket that is bolted to the engine.

HMM ..... maybe 02 were a tad different , if you need a down pipe PM me . you can use a 04 set up if needed it has a removable clamp.

I had my downpipe bracket welded a few years ago, and it's was easy. and still holding.
Like you said, drop 1/2 or totally remove plastic felder liner. If you could jack up front pass side frame, access above wheel is easier, (not necessary though).

Update - I took out the fender liner then took the truck over to the local exhaust shop where the welded up the crack for free!

Thankyou all for the replys.