Well it seems I too have been cursed by the leaky crossover pipe. Today about an hour into my trip from Maryland to Indianapolis I started hearing what sounded like a .... 'rough whining turbo' on the drivers side. Upon listening more it definately sounds like an exhaust leak. I've lost 1 PSI at full boost but havent really lost any power. I just got in so I'm letting things cool off for a few before sliding underneath and poking around for the hole.

The problem is I tried to change the damn thing a month ago but the nuts were so rusted that they flaked round. I'm going to start a daily regiment of soaking them with PB Blaster so try and loosen things up, then if need be hammer a 12 point socket onto the nuts to pull them off.

Would have been nice if this problem would have presented itself to me yesterday, so I could have grabbed the new x-over pipe, studs/nuts, and gaskets I have sitting at home. Guess I'm gonna have to have the woman send them to me when I get to Atlanta next week. What a blowzone.

Any recommendations on getting those dam nuts off?

Mine had bolts, not nuts. They have a Torx drive in the center so I did not use the outside hex at all. They came out easy with the impact wrench and I did not pre-soak them at all. I imagine I was probably just lucky that I did not break them off.

hmmmm..... wonder if I have the same thing..... Once i get to Atlanta I'll get under there with a steel bristle brush and see what I can see...

thx for the heads up homey

My truck is on it's 3rd crossover now, soon to be 3rd. I replaced bolts w/ stainless steel last time. I looked at the manifolds where the bolts go through, and the majority is rusted off. I'm affraid of the manifold breaking off around the bolts. Hope yours isn't the same. BTW I just ordered Stainless steel cross over from SS diesel, as well as stainless steel 4" exhaust. My whole banks system rusted out. Grrrr

yeah, I ordered my stuff awhile ago from SSD. SS crossover, new hardware and gaskets.

I looked and my pipe is rusted at the flange on the drivers side.

I looked and my pipe is rusted at the flange on the drivers side.

Same thing happened with mine. Good luck getting the bolts out. Out of the 6 on both sides, only ONE came out normally. The rest either were so rusted there was no head left to put a socket on, or they were so rusted in place the bolt head snapped off as soon as I applied torque to them. So I had to cut them out with a dremel and MANY cutoff wheels, lots of hours, sweat, blood, and cursing, and I had to drill out the remnants. It was amazing how fragile these bolts were, yet how strong they were when drilling them out. It was a job I hope to never repeat.

One thing I didn't try that may have helped prevent them from snapping was heating the bolts up first with a torch. I've heard that works very well.