flex pipe question 2000 3.8

on my 2000 windstar 3.8 the flexpipe braided wire has broken off of the ring that holds it around the pipe. When idling the now loose ring kind of jingles and I know is going to drive me nuts. Initially I was thinking that I'd just use some bail wire and wrap the loose ring around and attach to the braided part but I'm now second guessing myself. What are the odds that the flex pipe needs to be replaced if not now than soon? The whole exhaust is original except for 2 rubber hangers which I replaced ~1 year ago because they seemed pretty sketchy. Has anyone done this sort of repair?

Thoughts.

Piper

I would try a large ring clamp, this is actually a Ford approved fix for loose catalytic converter heat shields. If that does not do it, stainless steel flex joints are avialable from several sources - OEM ones tend to be triple wall (with the inner wall being fairly smooth).

Now if someone can identify the large chamber in the exhaust near the fuel tank, but forward of the rear muffler, that would be interesting.

The big rectangle/square unit that is just behind the flex pipe is the muffler.
The unit that is back by the rear wheels is a resonator.
Everything rear of the flex pipe is all 1 unit.....you have to cut.

Last week, I cut the loose rings off of the flex pipe.....they are not serving any purpose when they are just loose....not connected to anything.

Now......I bought a new flex pipe.....tried to remove the old one from inside the pipe forward of the muffler........
It is not coming out......and I have read a couple of other posts indicating this.....so cutting is the only way for my '96.
It looks like the new unit (Walker brand) is long enough that if I cut the pipe forward of the muffler (leaving as much as possible), I will have enough pipe to slide inside the remaining pipe forward of the muffler.

I used a caliper......new flex pipe is 2" OD, the pipe forward of the muffler is about 2 1/4" OD.

I bought a exhaust system clamp to put over the pipe forward of the muffler.....to hold the flex pipe inside.

If this works out.....I will let you know.

NOTE, this is on my '96, on your newer vehicle.....you will need to verify as things might have changed.

My big question is if the braided wire exterior is rusted off the ring then is the pipe beneath soon to be shot as well? Right now it's pretty nice weather-wize and as I'm garageless until next summer I'm doing the repair on ramps on my open driveway. If I need to replace this thing, now's the time. I don't want to have to do it mid winter and I REALLY DON'T want to have to take it to a shop mid winter so they can do it.


What is the general lifespan on the exhaust system on a 2000 windstar? I don't hear a lot of people complaining about replacing them.

Piper

Piper

On both of my Windstars the exhaust is still intact. I wonder if they downgrades the materials that they put in the newer Windstars?

Regards

Dan

From the "Y" pipe back is all original on my '96 at 202K miles.
My flex pipe, like yours, has the braiding broken completely free of the ring at 1 end on both braids.
How long before more problem?....I don't know.
I am planning on replacing mine, would have done it 2 years ago if I did not have to cut the end that goes into the pipe that comes out of the muffler.
I have the gasket for the "Y" pipe to flex pipe connection on order....and plan to do the repair when I get that part.

I replaced my "Y" pipe because 1 of the catalytic converters was rattling.....not the heat shield, but the internals.

If you replace yours, and have the OEM "Y" pipe......you have 2 studs that are part of the "Y" pipe that the flex pipe mounts onto.....
The nuts may or may not cooperate with you.

My walker "direct fit" Y pipe did not have the studs.......and so I used 2 bolts and nuts......I bought new stainless steel bolts and nuts to use for the "Y" pipe to flex pipe connection.

I am guessing that I damaged my flex pipe by letting it dangle when I replaced my "Y" pipe......lesson learned.

Heat shield on the rear most catalytic converter came loose (on my Walker replacement)......I put a big hose clamp type strap on it to hold it in place.
Front one is still solid.

The braid has been broken on my 96 for at least 8 years and about 60,000 miles. When I first noticed it I was thinking I would be replacing the flex pipe soon, so far so good and if it aint broke I aint gona fix it.

so just as a follow up I ended up cutting the ring off the exhaust flex pipe that holds the braided shield on. Once removed I slightly stretched the braided cover and used some galvanized steel wire to wrap thru the braiding on several segments around the exhaust. Once the wire was "sewn" thru I lengthened the braided part and tightened the wire. It worked great and the "jingling" is of course gone.

FWIW, my 2 cent fix.

Piper

Is it possible for you to take and post a few pictures for reference? I think it could greatly help any of us in the future if we encounter the same issues as you did. Its kind of hard to understand without a visual reference.

My '99's is in pretty good shape at 250 kmiles. But it has had little exposure to snow-melt-salt or ocean salt. I think salt is a big factor on underbody corrosion.

I would be inclined to replace it with new if there is much doubt. It would be a pretty sure a rear exhaust system wipe-out if the thing broke in-two.