98 Taurus, How Do I Remove the Dual Converter Y-Pipe?

[mshellhamer]

I have a 98 Taurus SE (Duratec Engine) with one of those dual converter Y-Pipes that retail over 600.00. Where the two pipes are connected by a piece of steel, there is a big crack all along that piece of steel on the lower pipe. I need to get it off off the car so I can weld that crack shut again and save about 1000.00 in parts and labor. But I can't seem to get to some of the bolts and O2 sensors that are tucked way up in there.
Is there a special tool, or a trick, that will make it easier for me? My Haynes manual isn't very helpful with that sort of thing.

[rhandwor]

Almost always you will need a long extension about 18 inches or a 12 and a 4 or 6 inch and a flexible socket which you could by at sears or a parts store. Normally you would use a 3/8 drive ratchet.
You might need a deep flexible. They make a flexable that you can change sockets on which in your case I would suggest.
Unplug the 02 sensors first and dis. neg. ground at the battery. Use jack stands unless you have a lift.
Always use anti seeze on installation so if a weld doesn't hold it will be easier the 2nd time to remove. Always use a small drill and drill the end of a crack both ends. As a crack will travel when you heat it. Use a ziz wheel and make a small grove along the crack so you get full penetration. I worked as an ASME inspector for a few years.

[mshellhamer]

Thanks for the tool AND the welding tips!

How about unplugging those O2 sensors? I can where the one up front plugs in but the other 3 seem so deep inside the car I can't tell where the connector plugs are.

[rhandwor]

Some times you have to loosen up the exhaust crossover. Loosen the nuts on the studs and then get your hand up. Think about it and in the morning things will work out. If you get stressed you mind or hands don't work right.
You can always check some of these links have pictures. You can check at the library. Alldata used to allow you to enter year vehicle and give 1 yrs axcess for around $20.00. Try alldata.com They had good coverage of electrical problems also.
I always buy a factory manual on ebay for my vehicles.