I had the same exact problem with that bolt when I did my lt's. The solution I came up with was to cut a slot in the flange of the header. Once I did that I was able to bolt it up without any other issues.

 

I just left that bolt out, it's sealed just fine, no leaks or anything. as long as all the othe bolts are torqued down that one wont make a difference specially if you use the mopar gasket. I just was not in the mood to try and cut the header to make it work when I did mine. We started late and finished late. maybe when we pull the heads I'll get them finished up the right way but I know a few guys that have just left that bolt out and have been running for years now just fine.

 

Ok, that's probably what I'll end up doing.

I wonder if pacesetter know of this issue. What a pain.

I would probably cut a slot in the mount, but I would be afraid that doing that would open up the steel to more corrosion and not last as long as it has with the ceramic coating.

I wonder if putting the pre-cat 02 sensor in the first collector would not give it a correct reading... being that it isn't reading from both sides. Then doing the one that's supposed to be post cat in the extension of the y-pipe, that way I wouldn't have to lengthen any wires and just do a non-fouler on the one that is supposed to be post cat.

Obviously then I would only have to plug the driver side one.

 

as long as you have the regular o2 (front one) in one of the holes, and a nonfouler with the o2 (rear) in another hole, you'll be fine. It doesnt matter which holes you use. just make sure the rear o2 has the nonfouler

 

Well, finally finished and tied. Nothing short of amazing.

I just left that bolt out and I'll have to go through and re-torque after I bring it to the exhaust shop.

Some notes to those of you reading if you're thinking about doing longtubes... be prepared to chop the transmission and do even more moving stuff around if you are going to do this mod...

I'm going to try and get someone to put a bung in for me tomorrow and finish the end up with a glasspack -- we'll see if they'll do anything with it at all.

 

Glad you got er done man!!

I hope to do mine tomorrow if my Y pipe comes in...
Im also going to go have the truck inspected in the morning, along with picking up some o2 bungs for the rears and some nonfoulers..

Now if it wasnt so damn hot......

 

Thankfully when i did mine I had no issues with any bolts not lining up. I did ziptie a few things out of the way even though mine are ceramic coated and I also trimmed that trans bell housing tab off the pass side. As for the extra bung, and 03 only has one cat doesnt it? So plug it with a fitting if you dont need it.

 

One thing you should do is check the alignment spacers/tabs. I had one that I found out that one was gouging into the header making a terrible grinding noise while turning AFTER it was sitting level on the ground, up on jack stands everything cleared but sitting on the ground there were a few things that need some "persuation" to get right.

 

Well, got her all done and bunged.

Just have to get a fouler and drill it out and I'll be set.

Hopefully it'll run better then.

 

Are yours the Pacesetters? That is weird that we both have 04's and your lined up and mine was way off for that one bolt.