I still need to replace the U-joint at the transmission, but when I last tried to remove the intermediate exhaust pipe I couldn't get it to budge. I had soaked the joints with PB Blaster overnight and was confused because I didn't recall having any trouble before when I replaced the transmission mount. I decided to give it another go this weekend and put the beast on the QuickJack so I could get under it and spray some more penetrating fluid to work overnight. When I opened the cabinet to grab the spray can something caught my eye, and I had one of those 'aha!' moments followed by 'oh no'. This is what caught my eye, a tube of this:

https://versachem.com/product/exhaus...-crack-sealer/

When I did the trans mount, I must have used that on the joints when I reassembled the exhaust, which would explain why the penetrating fluid wasn't working and why I could not get the joints apart.

Any suggestions on how to break the bond?

 

I suspect an oxy-acetlyene torch and get the parts red hot is probably the only way.

 

I second this. The SDS sheet lists Kaolin Clay as the main ingredient of what he used. Get it hot and brittle and some soft hammer taps might break it free.

 

3 bolts at down pipe, 3 bolts at rear, always drops right down for me. Where is it getting stuck?

 

The US spec 4 catalyst system doesn't use the 3 bolt olive in the front, it's a slip joint/clamp connection:

https://parts.jaguarlandroverclassic...tml?code=21914

 

Success!

I don't have access to an oxy-acetlyene torch, but a MAP Pro torch was hot enough to get it cherry red. Took several cycles but each joint finally gave up.

Thanks for the tip, much appreciated. I will NOT use that product on reassembly.

 

On reassembly I "sealed" the joints with high temp anti-seize. I guess we're never too old to learn.

 

Band clamps instead of the U bolt ones make a difference too. If you get an Easy Seal they will stretch over the joint and seal it very well.