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On my 240s, over the years I spent hours and verbiage disassembling the exhaust system to install new components, usually the back muffler and/or the under-axle pipe.
Never again. Last time around I did a cat-back replacement, and included a new cat (flunked emissions test). Wow, what a difference.
Toughest part it removing the bolts holding the cat onto the downpipe. Soaking overnight with P'Blaster works, most times.
After that it's a snap. Put something under the front muffler to hold it up in about the same place (I use a small floor jack). Remove the front muffler hangers. Remove the rear muffler hangers, left side first. Drop the front muffler, and drag the entire system out from under the car.
Assemble the new system, but not to final tightness. Install, pretty much reverse of the removal process. Use a new cat gasket, maybe new bolts. Put anti-sieze on the bolts - on clamp bolts, too.
Tighten the cat bolts all the way, then work towards the rear adjusting and tightening as you go.
No more pounding, swearing, cutting, peeling, hammer bouncing and hitting shin, and other such fun things.
Good Luck,
Bob
:>)
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