I received my crossover from Heath today and will get started on it tomorrow. Any hints or advice from yall that have already replaced this thing. I know the bolts might be a little rough and need some heat to move, but anything else I need to watch for or get out of the way first? Also is the clamp that comes with it to clamp the two pieces together suffecient or do I need to hit it with my mig?

You should have started spraying the bolts with PB blaster a few weeks ago, but now that its too late for that atleast spray them from now on.

Jacob

Would it be worth it to start spraying now and wait a couple of weeks to replace?

Hi Jeff,

I replaced my crossover pipe not too long ago, and I think that spraying the PB Blaster for more than one day would be ideal. Two weeks, however, might be over-doing it. You could let your bolts tell you what they need. You could spray it and just try to remove the bolts, but stop if they do not budge and re-apply some PB. In my case, I had sprayed it in for two days prior, but one bolt was still frozen after that. I re-sprayed and was able to continue the next morning.

The other thing that helped me was to move the downpipe. On my truck the downpipe made it difficult to access one of the crossover bolts. Once removed, I could access all bolts very easily using a creeper and by putting the truck up on Jack stands.

Good luck.

Jon

I guess I will wait a few days to start then. Thanks.

Ya, I was exagerating, but you seem to have gotten the point.

What about the clamp? Should it be enough or should I weld it?

I did my crossover and downpipe not to long ago... All I can say is, take your time, think it through, and don't fight with it, and it'll go fine, mine did, I've noticed that I have a slight exhaust leak from the clamp that was with the kit, I like the look of the band exhaust clamps some big rig exhaust company uses :D
If you have a mig, weld it... why not? I would if I had one

Just a thought...if you weld it, what will it be like to remove/replace in the future?

How can you tell if there is an exhaust leak? Aside from the obvious visual inspection, how do you tell? Thanks.

Jon

I did my crossover and downpipe not to long ago... All I can say is, take your time, think it through, and don't fight with it, and it'll go fine, mine did, I've noticed that I have a slight exhaust leak from the clamp that was with the kit, I like the look of the band exhaust clamps some big rig exhaust company uses :D
If you have a mig, weld it... why not? I would if I had one

When I replaced mine, I just sprayed it a few times for a couple of days. The bolts came out a lot easier then I thought they would...

I still don't have 4x4 because the crossover is in the way so I still have to get a custom fabbed one. For me putting it on was a little annoying because it was very hot when I was doing it, but luckily I got it all up there. When i was done I was black from head to toe... should have probably used a lift lol

Black!
I can see the soot comming out on the silver pipe. It's only a small one.

d

If the matting surfaces are true, and the stud nuts tightened evenly the flange should seal to the manifold. Alot of exhaust systems are held together this way. Mine doesn't leak...I know of two other friends who run these trucks (total of six trucks between them) with no exhaust leaks.

If the mating surfaces are true and the stud nuts are tightened evenly they should seal. mine doesn't leak...2 friends I know run 6 of these trucks between them and they don't have any problems. A lot od exhaust systems are held on this way...If you are welding and aluminized or stainess pipe to cast, what are the chances of getting a good weld?

If the mating surfaces are true and the stud nuts are tightened evenly they should seal. mine doesn't leak...2 friends I know run 6 of these trucks between them and they don't have any problems. A lot od exhaust systems are held on this way...If you are welding and aluminized or stainess pipe to cast, what are the chances of getting a good weld?


I am not welding to cast. The crossover is in two pieces. The clamp I am talking about holds the two stainless pieces of the crossover together.

http://www.heathdiesel.com/images/part/100368_2.jpg (http://www.heathdiesel.com/P/HDP1349/)

Sorry, my misunderstanding...Yeah, I'd weld too.

How can you tell if there is an exhaust leak? Aside from the obvious visual inspection, how do you tell? Thanks.

Jon


I can feel the exhaust coming out with my hand where it bolts on.

Thanks for the clarification. Now I'm wondering if I need to check that out :confused:. I guess since I'll be down there to change the differential fluid, I might as well "feel" for exhaust leaks. But damn- I have being so close to hot exhaust pipes!

Green, whose crossover do you have ? I need to replace mine but I have a differential drop to install and not sure if a stock crossover will clear the driveshaft ? Is there one out there that drops lower than stock ?

When i replaced mine, i Kroil'd it 2-3 times a day for about 3 days. Came off with no problems. The crossover i used was a 1 tube, no clamp or joint in the middle. Replace the "doughnuts" when you do it, they are cheap insurance $6 each at Autozone..etc.
Don

I doused the studs with pb blaster before replacing mine. The first two studs snapped. I put the torch to the others until they were dark cherry red. They backed out perfectly.

Wow... :eek: why did this thread have to get so confusing? Where was there mention of welding the crossover to the manifolds? And as far as getting it out when he welds it, he welds the 2 peices together, and unbolts the assembly from the truck ;) That works much better.... Anywho, I got to tig mine at work someday soon... It's the same 2 peice design :D But if I did have a welder at home, I'd have welded it as soon as I had it bolted up and clamped in place.

And I'd have an air intake done to... :mad: