All of a sudden my car got very loud today, so I jacked it up and the pipe going from the muffler to the flange (towards the front of car) broke. The muffler appears to be in great shape, but who knows, anyone have any suggestions on a replacement or repair that will keep me under $300???

 

You can have it fixed for under $50, go to any muffler shop and have them sleeve it...

They cut off both flanges and slip a metal ring around both pipes and clamp it down.

This is a very common problem on 5th gens.

 

The flange from the rear section of my car rusted off. I had a shop just weld it back on. Good as new!

FYI, this is a very common problem with our exhaust.

 

WOOOHOOOO, nice I had just found this http://cgi.ebay.com/ebaymotors/ws/eB...MakeTrack=true
on ebay, but I have a feeling that this no name exhaust would end up sounding like one of those fart cans on the little ricey cars.
Thanks for your help guys, I go check out my muffler shop tomorrow..

 

Please step away from the link...

 

I just had the same exhaust flange rust out as well. Unfortunately, Meineke refuses to do patch work and is trying to get me to purchase a whole new rear section.

 

aw shiznits.. thats where I was going to go today....... pepboys and dremel tool here I come.

 

One thing I've learned from minor exhaust work experience: go to an off brand shop. No name, no chain places will do anything for money as long as it's legal. Go, tell them the flange is rusted off and that you want it welded back onto the pipe. They will take the rear section off, unbolt the flange and weld it on to the pipe, bolt it back up and send you off. Should cost less than $40. GL

 

It's standard work and doesn't require much. They're not being ruled by the policies of the corporation they represent.

 

Mine broke as well. Couldn't get any shops around to fix it so I searched around for a local member to buy a muffler. I might be able to offer you my old exhaust, I'll post back if I can get it welded tho.

 

I went to a brake and muffler no name place, it was the only place I could find open on Sat morning, they charged me $80 to weld a new piece of pipe in. More than I wanted to pay, but I didn't want to wait till the holiday weekend was over....

 

hey frank!!!! I have a similar type on mine and it is quieter than my intake ( course it came with a silencer too. no power loss as far as I can see with it in). I took out the silencer a couple of times to see how loud it was, it was bordeline offensive. it does not sound like a fart can though.

 

they did that to me too, and charged me $120 for sleeve weld after i insisted

 

i paid $120 at mineki for sleeve and weld bastards

 

My flange connection just in front of the resonator has a leak. The flange on the resonator side is partly rusted so I don't have a nice flat surface so it doesn't look like a gasket could be sealed properly if I rip the joint open further.

Any suggestions? Will I have to replace that entire res asm just because of surface issues w/ the flange? It's not rusted beyond use; it just has part of it gone so it's thicker/thinner in some areas.

Suggestions? Take it (entire asm) off and grind it down???

Also, if I have to replace the part, is Walker a direct fit and quiet? I don't want a particular sound...just quiet like it used to be.

 

My exhaust broke right at the muffler a few weeks ago. I tried using a wire hanger to keep it from banging around underneath. I had a new section welded in last night, cost me $75, I'm happy now.

 

yep..super common. both my current 5th gens have had the issue. replaced the axleback on both but as has been stated-cheap fix for a muffler shop.

 

I had the same thing happen to me 2 years ago. took it to two or three shops and no one would touch it. Is the markup on mufflers really that high that they'd rather than sell you a part as opposed to labor? So, I took a dremel to it and some flex pipe from autozone and saved up money for a cattman cat-back. flex pipe lasted about 4-5 months, about what i expected

 

Mine did the same thing. I had an independent exhaust/repair shop delete the resonator and had new pipe bent to the broken flange that connected to the muffler. The factory muffler actually sounds good without being too loud with the resonator deleted.

 

80 bucks is cool but Damn that 120.....

 

buy a new 2 bolt 2" flange.....

 

Ok, so I pulled the trigger and ordered a center piece and rear muff asm. If I jack the rear up is there room to pull the stuff off? Is it so much of a pain that a shop's lift would be worth the money?

 

I just did this yesterday on my car, had to change out the resonator/extension pipe and the rear muffler section. You can do it on the ground, you just need to jack the back up as far as you can and the pipes for rear muffler section will clear the rear beams. It might help a little if you remove the rear right wheel but I was able to manuver the rear section above the beam using floor jack and jack stands without removing the rear wheel.

 

Ok. That's good to hear. Never done exhaust before; seems like getting it off is the worst part, rest is just fitting it up.

What brand did you buy? How does it sound? I just purchased Bosal, so will have to see...

 

Samething happend to me about 3 months ago! But I just said hell with it and did a magnaflow custom catback for under 400 bucks. Couldn't be happier....

 

It's rather easy can be done in about 30-45 min! That Bosal Catback is a pretty good Oem replacement ... and you will be happy! Just kinda curious about LoudSteve's custom magnaflow setup.....like which resonator and rear muffler did you utilize?

 

Bosal rear muffler asm wont clear the beam. Car is up quite a ways! Help!

Also, dummy me can't remember fit....does it go between the U-shape part and the floor of the car? Or the next open spot below that? Can't remember!

Need help asap!

 

is that replacement any better (eg. stainless)?

 

Believe me if this 3" Cattman can fit (which has longer tips and fatter tubing) Bosal shouldn't pose a problem!

 

Thanks for all the advice above, really saved a lot to wield scrap flex pipe in the buy a whole new exhaust!

 

Also thought I'd share if you're in or around Manassas, VA:

Master Care Auto Repair
9111 Industry Dr
Suite G
Manassas Park, VA 20111
(703) 393-1057

Its a small shop, has a lift, and does custom exhaust (I think that would be integral for anyone looking for a shop that can weld and easily fix this issue). I walked in on a Sunday, Obvidayo? fixed it right there, and for real cheap.

If you have the tools you could do it yourself.