Flex pipe broke on '98 Windstar 3.8l

lidation · #1 07-10-2007, 01:05 PM

My car ('98 Windstar 3.8L, 85k miles) got freaking loud since 2 weeks ago and the noise came from around the CAT. A local muffler shop took a look at it and told me that the "flex pipe" was snapped and most of the sound came from that region. Fixing the flex pipe will cost me $470 including labor and materials.

I am not dumping $470 into this old beater van so I took it home.

Now what?

1. Do I have to live with the loud noise? (My BMW is actually louder than that, but that was from my performance exhaust system. So I can actually live with it except that my wife wouldn't.)

2. Any alternatives? I check y2kford but couldn't find the "flex pipe". They only have a thing called "connector" listed as $137. Not sure whether they are the same thing. Anybody shed some light?

RickMN · #2 07-10-2007, 01:09 PM

Check with a local auto parts store and see what the flex pipe costs. It should be around $200. This is something you can put in yourself. Otherwise, check around for a "non-chain" muffler shop. They usually have better pricing. As far as a patch, there is no such thing for this particular part.

busboy4 · #3 07-10-2007, 04:17 PM

Hi
Here is a Rockauto part:

http://www.rockauto.com/catalog/x,ca...parttype,10038

Not a lot cheaper but it shows a diagram if you click on the more information link.

Good luck

garync1 · #4 07-10-2007, 05:17 PM

RICKMN is right, had one to go on a 1997 Chevy Malibu just before I traded it in on a Freestar. I tried to come up with some way to patch it but failed took it to a muffler guy I know personally and the darn part was still 105.00 bucks at cost. Others wanted 150.00 to 200.00 for the little crap pipe. You need it on some cars with front wheel drive because of the movement of the motor and trans.Versus exhaust mount location.Needs a little room for some movement between exhaust manifold to exhaust system In other words if it did not have it you would be in the shop for exhaust repairs daily. Others even rear wheel drives use it as well but more with compact engine compartments and front wheel drives.Keep in mine its a weak point in the exhaust system and have the cat checked as well for sometimes from what I was told from my muffler guy it can be a sign of a cat going bad.. Mine checked out ok..

wiswind · #5 07-10-2007, 07:54 PM

I bought a Walker Flex pipe from Rockauto for about $100.
I have not installed it yet.
I went to install it and was not able to get the unit loose from the front part of the muffler.
As mine is not so bad....I have not messed with it further.

As mentioned......the "Y" pipe (that includes the catalytic converters and piping to the exhaust manifolds and to the flex pipe) is one solid unit that is bolted solid to the engine.
As the engine rocks and vibrates on it's mounts, the flex pipe provides the ONLY point of flex for the exhaust forward of the muffler.

From looking at the exhaust system, you can replace the "Y" pipe, and the flex pipe as single assemblies.....the rest of the system is welded together, although you buy it in indivitual parts......It would be tough to replace it otherwise.

lidation · #6 07-10-2007, 07:57 PM

Quote:

Originally Posted by garync1

RICKMN is right, had one to go on a 1997 Chevy Malibu just before I traded it in on a Freestar. I tried to come up with some way to patch it but failed took it to a muffler guy I know personally and the darn part was still 105.00 bucks at cost. Others wanted 150.00 to 200.00 for the little crap pipe. You need it on some cars with front wheel drive because of the movement of the motor and trans.Versus exhaust mount location.Needs a little room for some movement between exhaust manifold to exhaust system In other words if it did not have it you would be in the shop for exhaust repairs daily. Others even rear wheel drives use it as well but more with compact engine compartments and front wheel drives.Keep in mine its a weak point in the exhaust system and have the cat checked as well for sometimes from what I was told from my muffler guy it can be a sign of a cat going bad.. Mine checked out ok..

Thanks for clarifying all these. I had worked on the exhaust system on several RWD cars before and have never seen these "flex pipe". Now you explain it well that it's because of the FWD layout the engine and tranny will have limited movement related to the exhaust pipes.

I will order a pipe for $110 and do it myself. Monroe wants $470 for this simple job is just outrageous. Well, they claim this part cost $400 and plus one hour of labor.

Anyway, I'll keep you guys posted. While I'm down there I will change my transmission oil as well, with the Motrocraft Mercon V.

lidation · #7 07-11-2007, 11:24 PM

I just bought an improved version of the OEM flex pipe from an eBay seller called Chris. He claimed it will be bolt right on. He aslo sold me the installation kit for $9 extra. Nice deal! I just paypal him. I will keep everybody posted of how this pipe worked for me.

http://cgi.ebay.com/ebaymotors/Ford-...spagenameZWDVW

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