I have a 1995 K1500, 5.7 TBI, 5 speed manual transmission with a New process 241-c transfer case. I am getting ready to pull tranny/transfer case, but I am concerned if I must remove its exhaust cross member and cat/converter that might possibly restrict me from lowering transmission with jack.. Removing it would require a lot of cutting off or breaking off old rusted exhaust bolts and sawing off exhaust pipe behind converter. This is a fine truck (except tranny issues) that I have maintained since 2001, but a local shop wants 1200 bucks to do the job. Unfortunately, that is just too much money for this old truck. I have tools and have performed similar repairs before. There are a few YouTube videos on the WWW, but none explain exhaust solutions. For now, I can work around exhaust to access wiring, bolts, etc, but it requires more time since I am in a restricted space under my truck. If I must remove exhaust in order to drop tranny, then I should do it now? I can buy a Harbor Freight Scissor type Transmission jack that should be able to pull out transfer case and then tranny. Any suggestions on my exhaust issue?

 

If the exhaust has to be removed for access, it is what it is.

 

But, as I implied, I don't want to remove it, if I don't have to...

 

I haven't done a 95 but 2000 and up require y-pipe removal. the only way to get rust exhaust bolts off without damage is heating with a torch. This is not a fun job without a hoist, on your back in a driveway.

 

Thx for replying. I have removed lots of hardware, drive shafts and wiring. It looks like I can back it straight back 5-6" and down and out, w/o binding in the pipes. However, the manual shifter stud is going to hit the floor board if I bring it back 3". I have removed the long floor shifter (female) , but there is a 3-4" shifter stud (male) that I have to figure out how to remove. It will jam against the flooring. THX .

 

Check to be sure that the stub can't be removed as well. Lots of times there is a threaded lock ring or you push down on the spring loaded stub and turn 1/4 turn and it comes out. Don't know for sure but is worth a shot.

 

NV3500 4 bolts hold the shifter on, should be able to access that from the top inside the truck under the boot. Pretty certain that you are going to have to remove the exhaust, once you remove the transfer case you will have to remove the crossmember and let the trans down a bit so you can reach the top bolts of the trans with a long extention (24"). The transfer case is a pain because you have to lift it over the suspension cross member to the rear.

 

Thanks to all. There's a few videos on similar trucks and procedures, but not specific to mine. There appears to be a rubber boot on the top tranny sub/stud that I can access. I'll try to remove it. THX! If I have to remove y pipe, I will have to cut off and later re-weld or use couplers. That pipe is old and rusty, so I don't know if there is sufficient metal to hold a new weld. I wanted to leave Cat on the exhaust system, but I may have to discard due to all my needed cutting. Now, be the time to add a header system? I wanted to keep this truck for my hunting, since it has been incredibly reliable. My wife just paid over 300 bucks to have her Duramax's DEF drained because it went bad in the truck or was too old. We abruptly learned that DEF fluid has a small shelf life and none of the stores put expiration dates on their containers.