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So, the final diagnosis on this was a failed lower exhaust mount. We now believe, as others have pointed out, that the "something else is wrong" was the failed lower exhaust mount. With that lower mount failure, we are speculating that the bolts on the upper mount couldn't handle all of the loads and stresses. Curiously, I inspected my repair records, and found that the last time i had this happen back in 2006 just after i bought the car, one of the upper mounting bolts had failed, but the mechanic also installed a missing lower mount bracket. So, that correlates. Exhaust is back in with repaired upper mounts and new lower mount bracket.
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