Exhaust Flex Coupler

[Sandfobs]

I purchased an EXHAUST FLEX COUPLER from the store throughout the week and planned to replace it on the weekend. I was successfully able to remove the old one without any problems and when I put the new one on it's too big in diameter around a quater inch......I would like to know if the clamps that I have for it will compress it enough to fit?

[mightymoose_22]

The store should have adapters to make it fit.

[zzyzzx2]

You could also mail order one the right size.

[Sandfobs]

Ok I took it back and went through the system again and yes it was the wrong one, when it came in I installed it I noticed the flex was really flexed but it's on and it's quiet once again. What I did and what I used for install.

Measure the diameter of your intermediate pipe and be sure you order the correct diameter EXHAUST FLEX COUPLER. Item only required is muffler cement which I found for just under 10 dollars, a dremolo with metal cutting disc, I bought two just in case but one was fine.

To cut the EXHAUST FLEX COUPLER off, on each end there are sleeves that slip onto the intermediate pipe, these can't be pryed off they must be cut off horizontally along the old sleeve of the EXHAUST FLEX COUPLER, I made two slits running parrellel to each other on both ends of the sleeves. Used a hammer and flat head screwdrive and hammered under the sleeve at the slits I made and the EXHAUST FLEX COUPLER came off very easily.

Use the dremolo to clear off any cement still remaining on the intermediate pipe and use your new EXHAUST FLEX COUPLER to be sure it slides on smoothly on each end then remove it to prepare for installation.

I removed the plastice clamps earlier that holds the whole muffler system in place and placed these clamps back into position leave only one loose to have room to install the EXHAUST FLEX COUPLER. Wash and dry each intermediate pipe, hammer on the U part of the clamps on both ends of the new EXHAUST FLEX COUPLER then use the muffler cement inside both ends of the EXHAUST FLEX COUPLER and on both ends of the intermediate pipe then place EXHAUST FLEX COUPLER into position. Once in place the other portion of the clamps maybe difficult to get on, I used a clamp to squeeze the threaded ends together so the end piece of the clamp could slide on. Tigthen up and let the engine run for 20 minutes to 30 minutes to allow the muffler cement to cure and your good. Sometimes it's alittle loud but it will quieten after it cures.

[Arnoldtheskier]

On my 93 SW the stainless flex coupler was rusted/rotted through at the exhaust pipe right where the cat is.Looked like a flex coupler..man those things are not cheap! $50 or so here. I did not
t really have time to do the job properly..had to go skiing the next day haha..so I wrapped a piece of aluminum around the area to encompass the back part of the front ex pipe where the cat is and the flex coupler. This'll work for a while..till I can fix it right. I took it apart gooberred it up with muffler cement and a few clamps. Did the instructions let it warm shut it off/wait whatever the instructions were..some of them are different and there are a bunch of different glues/cements etc.

Next day lasted about 5 minutes haha..got noisy but did not get noisy enough to get stopped. The car seemed to be better on gas. Seemed. I dunno..maybe the stations/pumps/gas/I dunno. After several more trips back and forth skiing (340 k or so..200 miles or so) the car now noiser was for sure a good 5 mpg better!..but objectionally noisy..not enough to ge t stopped.

The following week I fixed it just about perfect and whisper quiet. I simply took off the flex joint,cut the ex pipe at the cat clean and the ex pipe clean and put another pipe in there(with the right cheap pipe adaptors)and clamped it up. Who needs that flex joint anyway.

And I lost that 5 mpg that I had gained. Guess I got it from less backpressure..

Those kinds of things seriouslly bother me. So you know what I did next

I took the pipe out that I had just put in..and I fiddled around with the pipe sizes/adapters/clamps etc. I wanted some leakage..less backpressure. I ended up with a combo of pipe,adapters,clamps that had some leakage due to the difference in size. It was next to impossible to clamp properly..no kidding due to the difference in pipe sizes SOooo..I drilled through both the ex pipes and the new pipe and the adapters and ran a stainless steel screw right through both sides and double nutted it.

It was for sure not whisper quiet..and yes..it was a bit noisy..not get pulled over noisy..I take people in my car no one ever remarked..crank the tunes up a bit. And it also rattled a bit

Got my 5 mpg back!
That repair lasted for years

When I had to go through emmission I wrapped the joints in muffler/exhaust pipe tape/ bandage nd goobered it all up..ya..like about a few minutes before the test haha. Wokred. Passed easy

Last year when my next Escort was like new..in the winter this truck ahead..all of a sudden chunks of ice the size of car batteries start litterring the road!! Nice. I can't avoid them. Over them I go..my car got noisy right after. Up on the stands. Sure. Nice. Bent the bracket that holds the cat to the trans/engine,broke the weld off the ex pipe where the bracket attaches to it,broke the flex joint at the back of the ex pipe,bent the ex pipe where it goes into the muffler,broke the muffler hanger off the muffler.

I did the same flex joint repair I did on my last Escort. So far so good..even with no bracket on the ex pipe near the cat where the bracket that attaches it to the trans/engine. Patched it up

I dunno..last year..what was up with the ex system prices for this car?? OUCH. Cheapest ex pipe around here was like $230. Sure..it is a wagon..but OUCH. Not installed. I managed to patch the old one up.
The cat wasn't bad at about $150..and the muffler at about $150 was waay too much too. I did not have to buy them.I shopped around..maybe they are down this year.

[Sandfobs]

Wow.... LOL... I think I would consider the patch over new if I could get 5mpg better. LOL Great post and thx for the info.