I have a 2005 AWD with the 3.5l. My flex pipe to the cat broke so I got a new direct fit converter assembly from Magnaflow ($202.99 shipped to the door). Went to remove the old piece and all 3 bolts snapped off. I tried heating the flange lobes and spinning the studs out but I can't get any torque on them. I tried cutting the studs off and drilling them out with an angle drill, but I can't get any pressure on it. I already have about 70 hours into this. I would like to remove the rear exhaust manifold so I can put it on a bench and drill the studs out, but I don't see any possible way to do it without splitting the frame and dropping the transmission. I tried with a mirror to get the manifold bolts from above but I can't seem to get any wrench to fit in between the firewall. Has anyone been able to remove the rear manifold without removing the engine or transmission?

 

I ended up removing the cross piece of exhaust and that gave enough room to get the manifold bolts out.