[lordvoldemort]

I noticed that I have a leak where the flange connects the Y-pipe to the muffler pipe. The flange is rusted and the connection is loose and hence the leak. There are no holes and the pipes seem to be okay. I tried tightening it and it helped but am not sure how long it will last because of the corrosion in the flange will keep getting worse, especially in the North East Winter. The flange I am talking about looks something like the attached picture.
My questions are
1) How easy is it to replace the flange ? Are the pipes and muffler welded to the hanger ? It seems like I would have to pull out the muffler/pipe in order to replace the flange.
2) Or should I cut the pipe around the flange and install a pipe-adapter/coupling with a clamp and join the pipes ?

This is a 2003 V6 Mustang.
Thanks in advance for your inputs.

 

[davidcseifert]

Easiest way, cut out corded section and just weld in a piece of pipe, don't have to pull an of the exhaust to do it....

 

[trashpickinman]

This is what I did on my 96 a few months back in the picture. The original exhaust flange was rusty and bolts were so rusted I couldn't tighten or loosen them. It took about an hour using only hand tools to cut things. I just grabbed an adapter and a length of straight pipe with the expanded section on one end, and several clamps. I believe the "Y" section was 2 1/4 inches and the muffler side was 2" in diameter, double check yours to be sure.

I had to remove the muffler from the hanger to swing the muffler and pipe back far enough to put everything back together. Seems to be holding fine.

edit: I just looked at my picture a bit closer. A little bit of escaping exhaust, but nothing major.

 

[lordvoldemort]

Thanks for the post.
Was your muffler or pipe welded to the hanger ? How hard was it to remove from the hanger ?

This is what I did on my 96 a few months back in the picture. The original exhaust flange was rusty and bolts were so rusted I couldn't tighten or loosen them. It took about an hour using only hand tools to cut things. I just grabbed an adapter and a length of straight pipe with the expanded section on one end, and several clamps. I believe the "Y" section was 2 1/4 inches and the muffler side was 2" in diameter, double check yours to be sure.

I had to remove the muffler from the hanger to swing the muffler and pipe back far enough to put everything back together. Seems to be holding fine.

edit: I just looked at my picture a bit closer. A little bit of escaping exhaust, but nothing major.

 

[trashpickinman]

Sorry, I was mistaken. It's been a while since I did this.

Just under the rear bumper and right above the exhaust tip is a rubber hanger that holds up the rear part of the exhaust, that is where I pulled it loose. I think I sprayed some WD-40 in the rubber part to get it to come out easier.

Total on parts was about $20. I drove the front end up on ramps, the rest was just elbow grease.

 

[lordvoldemort]

Thanks again.
btw, do you remember if the dimensions you mentioned above (2.25 and 2) is the ID or the OD ? I'm looknig at advanceautoparts website and it has adapters with both ID and OD.

 

[trashpickinman]

The part numbers I used from my receipt:
548623 - "Tailpipe"
517200 - "Muffler Clamp"
517214 - "Muffler Clamp"
548521 - "ADPTR2-1/4ID X 2-1/8OD"


But please double check your own exhaust dimensions, more than likely they are the same. But I'd hate for you to go out and buy exactly what I bought and have them be the wrong size.

 

[Yadkin]

Exhaust piping is technically a "tube", so the stated size is the OD. To extend it with locally stocked parts, use a part that has as the tube dimension ID on the upstream end, and an OD matching the ID on the downstream end. The tube thickness is typically 18 gauge, which is about 0.05" thick, so the correct OD to match the ID of a 2.50 inch tube is 2.40".

A better way to make a repair is a un-stepped band clamp. This is a wide stainless steel clamp that wraps around the OD of two sections butted up together. Most of your local stores don't carry them though.

Of course the best thing to do is to replace the old Y pipe with a true dual exhaust.

I don't recommend using WD-40 to lubricate rubber parts since it degrades the rubber. Better to use silicone that actually protects it.

 

[lordvoldemort]

Thanks very much. Appreciate you looking thru the receipts.

The part numbers I used from my receipt:
548623 - "Tailpipe"
517200 - "Muffler Clamp"
517214 - "Muffler Clamp"
548521 - "ADPTR2-1/4ID X 2-1/8OD"


But please double check your own exhaust dimensions, more than likely they are the same. But I'd hate for you to go out and buy exactly what I bought and have them be the wrong size.

 

[lordvoldemort]

Thanks for the input. Will keep you guys posted.

Exhaust piping is technically a "tube", so the stated size is the OD. To extend it with locally stocked parts, use a part that has as the tube dimension ID on the upstream end, and an OD matching the ID on the downstream end. The tube thickness is typically 18 gauge, which is about 0.05" thick, so the correct OD to match the ID of a 2.50 inch tube is 2.40".

A better way to make a repair is a un-stepped band clamp. This is a wide stainless steel clamp that wraps around the OD of two sections butted up together. Most of your local stores don't carry them though.

Of course the best thing to do is to replace the old Y pipe with a true dual exhaust.

I don't recommend using WD-40 to lubricate rubber parts since it degrades the rubber. Better to use silicone that actually protects it.

 

[lordvoldemort]

I was able to just tighten the flange and for now it's not leaking. I think I am going to replace stock exhaust with a fllowmaster in the spring. Thanks for all the help.