Over the weekend I replaced my auto. transmission and installed a new trans mount. When I went to put the exhaust back on I found that the exhaust pipe coming off of the manifold is now at a different angle making the catalytic converter rub against the bottom of the car.

I guess the new mount was thicker and raised the back of the engine.

Has anyone came across this before?

Kyle245

How are the engine mounts? If those were soft and letting the engine down in front, the rear of the engine would pivot upward on the tranny mount and the exhaust downpipe would also point upward.

Had the same problem 2 months ago with my 1984 245. My car had the crossmember shims in place and did not have floor damage. First attempt was to bend header pipe in place using a big lever. Things moved, but pipe did not bend.

Finally took the header pipe off, filled it with sand using a lot of tapping to get it to pack down. Ends of pipe were plugged with wads of newspaper tamped tightly in place.

Made a measurment tool to check bend progress by marking a spot on the floor next to a wall for the flange at the engine end and a mark up on the wall for the cat end.

Used my Harbor Freight 12 ton press with soft wood blocks on both sides of the header and made a couple of presses resulting in a bend increase of 1/2" at the cat end of the header. The sand and the wood blocks prevented the pipe from collapsing.

Removed newspaper and sand and reinstalled the header. Now the clearance matches that on my other two 240s (roughly 1/2" at the closest points).

Good luck,

Tatra Mike

1984 245 "Buster" (off with the kid)
1985 245 "Cosmo" (at anchor in the drive)
1985 244 "Alfsen" (plugging along)

Hi Kyle,

The one thing that comes to mind is the spacers under the cross member. Were there any before? and, Did you replace them? If there are none there now, lower the crossmember until you have the proper clearance. Measure the distance from the crossmember flange to the rail and cut a spacer for each side. If you are off over 1/2" re-check the transmount installation.

Good Luck,

Big Harry

Hello Harry.

The spacers are in place. I thought about adding more spacers but it just seems wrong at this point.

I also thought about heating the exhaust pipe and try to bend it down but its two pipes that come together so that idea might be too difficult.

I'd be tempted to just Conan the thing back down with a suitable long lever. First, however, see if loosening the manifold nuts will give you a little room to pivot it down (unless you are match-ported, of course). Then, perhaps, adjusting the various clamps may give you a little room, too.

Exhaust systems are well known for being in the way regardless of car make and model. Replacement systems doubly so. I expect a local shop would try to lever the bugger down first and then go with a cut and tack proceedure if levering didn't work.

You could always remove the cat if your local laws allow...

Mike!