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Old 05-13-2009, 10:39 AM   #2 (permalink)
wstar
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I'll add a few points:

(1) I don't think spacing that crossmember with washers is a great idea. That's got to affect the structural rigidity of the piece (and the car as a whole).

(2) If you're going to have to make adjustments because it hit the crossmember the first time you dropped the jack(s), do it right then. If you drive the car for a while first and then go back to fix it, you'll ruin a gasket or two when you go back and loosen/readjust flanges on gaskets that have already burned in from exhaust heat. That's how I got my leak, and then I had to get new gaskets and take the Y-pipe back out again and fix that.

(3) Experiment with jack placement on the exhaust. I think the right place to raise it from is the little crossbar on the front Y-pipe section now (without trying to jack the rear, although you may want to hoseclamp those rear hangars as mentioned above), but the ideal setup may be more complicated than that.

If you tighten everything and pull the jack(s) and it still hits, get back in there and get it right the first time, it's going to take some finagling. Be sure when you're manipulating it with loose flanges that you also make sure the slip joints are allowed to slip as well. If they bind up, pop them with a rubber mallet to let them move.
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