Thanks to my BB brothers, I came up with a solution to fix the catalytic converter that fell off the header pipe on my trusty Brick. But I can't weld. So I took it to a local mechanic who welds. My instructions: weld away. His response: replace the header pipe with an aftermarket part. Thank you. Cranked it up and the thing let out a full throated roar. Shuddering and roaring like the goddamn cowardly lion in the Wizard of OZ. But if you're standing next to it, it sounds fine. Only when you get in it does it rumble and feel like it's falling apart. I couldn't figure out where it was coming from.

I got it home and inspected the engine first. I noticed the P/S belt was jiggling and loose and the cap was broken and not closed tight -- well to be honest, the cap has been broken awhile and I managed to get it on there some kind of way but it would not tighten and I can't find another cap. I tightened the belt, but noticed the pulley was pretty loud. The rumbling continued.

I put the car on jackstands, started it, and put it into gear. I saw right away that the reverse light switch attached to the tranny was sheared clean off by the spinning drive shaft. It's supposed to be in a clip and was swinging free. And the tranny is sitting on the cross member.

The question is this:
Is there a hole in the crossmember to fasten the tranny mount to, or does it just sit on there. My tranny mount is about the size of Abraham Lincoln's NBA playbook. I have no idea what it looks like, but i ordered one from Groton.

How can you tell if a header pipe and catalytic converter are properly married? Can you see the doughnut gasket in there that's supposed to be there between them. How can you tell if it's leaking? I should have done that job myself.

How do you change the P/S pulley, and should you change the low pressure and high pressure hoses when you're doing the job?

If I'm gonna lay in the cold fixing this thing I might as well do it right.


Thank you.

Cuddy

Maybe it is just late at night, but I am confused.

Are you saying all these problems surfaced only after this mechanic worked on your exhaust?

Tranny mount is an easy job. Use a jack to support the transmission while you swap out the mount.

To swap a PS pulley requires a special puller for a Ford/Saginaw PS pulley- I bought one at Pep Boys back when they used to carry some real tools (Lisle). Did you try a new belt first? That may quiet it down some. Also, the alignment of the pulley can be affected by worn PS mount bushings. Those are also easy to replace.
--
'92 240 wagon, 285k, '90 240 sedan 229k

What Blue said, the mount is hidden up at the top of the bracket held on by four bolts right behind the tranny.

You might as well double check your motor mounts, they tend to go all about the same time.

I would try and tighten the belt first. Loosen the two 13 mm nuts and bolts, but do not take them off. Then crank on the 10 mm righty tighty until the belt is snug. Then tighten up the 13 mm and see what the gets you.

Good Luck,

Paul