Muffler problems

Just started the van and it sounds like a rice burner, looked underneath and found the pipe after the cats that connects to the muffler the little gasket is missing and the nuts and bolts are rusted. can this part be replaced? or do i need to replace the whole pipe. i will try to include a pic.

http://i593.photobucket.com/albums/tt18/toughguy41/DSC00502.jpg


http://i593.photobucket.com/albums/tt18/toughguy41/DSC00504.jpg

http://i593.photobucket.com/albums/tt18/toughguy41/DSC00505.jpg


thanks all.

i would take it to a muffler shop , let them worry about the rusty bolts. If you try to take them off it looks like they will brake off in the flange,unless you have a hoist it is a pain trying to drill them out

From what it looks to me in picture #3 your flex pipe is also coming apart. Yes they can be a pain.

From what it looks to me in picture #3 your flex pipe is also coming apart. Yes they can be a pain.


ok, but can it be done? what size nuts and bolts will i need?

It looks to me......in that first picture.....the studs are toast.......so they need replacement.
They DO sell the gasket.
On my '96, at the front, the "Y" pipe had studs....and nuts went onto the flex pipe side.
At the muffler end.....the flex pipe fit inside the pipe from the muffler....and I was unable to get it to slide out.
The flex pipe is sold as a separate piece as well.

In short.....there are no threads to put a nut onto the bolt......so I would try knocking the bold out.......and go to AutoZone and try to buy bolts, nuts (and lock washers) that will fit into the hole.
Don't worry about the thread pitch.....as you will be buying nuts and bolts.....so you can match the threads up at the store.......all you need to worry about is the thickness.......to fit through the hole.

HOWEVER.....I STRONGLY recommend that you support the end of the flex pipe BEFORE you disconnect it.....
If you let it dangle.....you will almost certainly damage it.
A loop of wire around the pipe and something on the vehicle will hold it up.

It looks to me......in that first picture.....the studs are toast.......so they need replacement.
They DO sell the gasket.
On my '96, at the front, the "Y" pipe had studs....and nuts went onto the flex pipe side.
At the muffler end.....the flex pipe fit inside the pipe from the muffler....and I was unable to get it to slide out.
The flex pipe is sold as a separate piece as well.

In short.....there are no threads to put a nut onto the bolt......so I would try knocking the bold out.......and go to AutoZone and try to buy bolts, nuts (and lock washers) that will fit into the hole.
Don't worry about the thread pitch.....as you will be buying nuts and bolts.....so you can match the threads up at the store.......all you need to worry about is the thickness.......to fit through the hole.

HOWEVER.....I STRONGLY recommend that you support the end of the flex pipe BEFORE you disconnect it.....
If you let it dangle.....you will almost certainly damage it.
A loop of wire around the pipe and something on the vehicle will hold it up.


Thanks wiswind, by looking at these pics should i change the flex pipe too? is there a kit i can buy for this problem? and is there a "name" for the gasket besides gasket? anysize on the studs/bolts?

when you go to whatever auto parts place just tell them the year and engine on your van and they'll have a picture of the parts and fasteners you need. They do sell a "c" clamp style stud replacement that will work in a pinch. I'd do this only if you can't get at the job for a little bit of time. I'd be replacing the flex pipe as even if you save it during this repair, you'll be replacing it within 6 month IMHO.

when you go to whatever auto parts place just tell them the year and engine on your van and they'll have a picture of the parts and fasteners you need. They do sell a "c" clamp style stud replacement that will work in a pinch. I'd do this only if you can't get at the job for a little bit of time. I'd be replacing the flex pipe as even if you save it during this repair, you'll be replacing it within 6 month IMHO.


thanks northern piper, will work on this this weekend. can i sub the resonator and use straight flex?

the quick answer is probably. I think I'd be sticking with replacement parts that are the same myself. Exhaust stuff isn't that expensive when you get it from an auto parts place. Changing a resonator for a straight flex can cause different pressure within the system that can muck up other things and ultimately be more of a headache than the few bucks saved. IMO, I'd use aftermarket 'identical' replacements.

For clarification.......
The flex pipe is available as 1 unit.........although I think you might end up cutting the back off and using a sleeve to install the new one.
Walker has a nice one.......available on Rockauto.

Directly behind the flex pipe is the muffler....a big square or rectangle unit.
Then a pipe goes back to the rear......and behind the rear wheel is the resonator.
There is SUPPOSED to be a hole in the bottom of the resonator for the water to drain out........so water draining out the bottom of the resonator is NORMAL.

The muffler and all the way back through the resonator and tail pipe is ALL ONE ASSEMBLY........
I would not mess with it unless it is clearly defective.
My '96 3.8L still has the original assembly.....including the flex pipe......
It has a different "Y" pipe with the 2 catalytic converters......because one of the catalytic converters was rattling from the inside (not the heat shields).
I bought a new flex pipe a few years ago as mine was looking like it was starting to fall apart.....but it is still hanging in there.

For clarification.......
The flex pipe is available as 1 unit.........although I think you might end up cutting the back off and using a sleeve to install the new one.
Walker has a nice one.......available on Rockauto.

Directly behind the flex pipe is the muffler....a big square or rectangle unit.
Then a pipe goes back to the rear......and behind the rear wheel is the resonator.
There is SUPPOSED to be a hole in the bottom of the resonator for the water to drain out........so water draining out the bottom of the resonator is NORMAL.

The muffler and all the way back through the resonator and tail pipe is ALL ONE ASSEMBLY........
I would not mess with it unless it is clearly defective.
My '96 3.8L still has the original assembly.....including the flex pipe......
It has a different "Y" pipe with the 2 catalytic converters......because one of the catalytic converters was rattling from the inside (not the heat shields).
I bought a new flex pipe a few years ago as mine was looking like it was starting to fall apart.....but it is still hanging in there.



thanks again wiswind, northerpiper, i am looking up the parts i need and the part in the pic 1 resenator is $150 bucks alone!!! the gasket $3.00. besides rockauto i am still looking around.

toughguy5, check this item number out on ebaymotors.com: 350161597045
it is for the flex pipe with gasket but no bolts.

toughguy5, check this item number out on ebaymotors.com: 350161597045
it is for the flex pipe with gasket but no bolts.

Great, thank you. well i bought home from work a aceltayne torch and burned out the bolts and replaced the gasket and its working great. but i will keep this ebay site in case the pipe goes, thanks again everybody.