Rusty Exhaust System for '98 3.8L

[lidation]

The flex pipe of my '98 3.8L (80k miles) was leaking and this car is freakin' loud. So I bought a flex pipe off eBay and going to replace it. Crawling under the car reveal that the muffler is pretty rusty too and so do the rest of the exhaust system.

I haven't started the job yet.

I'm just wondering, how are the exhaust pipes look on your Windstars? Have you replaced any flex pipes, mufflers or resonators?

[96wWindstar180K]

lidation
The muffler is real rusty. I just replaced my flex pipe. I actually had Merlins Muffler do it for $20.00. I bought the pipe. I still have the original exhaust and live in Illinois we use salt in the winter and it still held up well. The new flex pipes are a different configuration at least for the 96s. I bought my pipe from Team Ford in Nevada. I didnt price the muffler shop.

[lidation]

Originally Posted by 96wWindstar180K

lidation
The muffler is real rusty. I just replaced my flex pipe. I actually had Merlins Muffler do it for $20.00. I bought the pipe. I still have the original exhaust and live in Illinois we use salt in the winter and it still held up well. The new flex pipes are a different configuration at least for the 96s. I bought my pipe from Team Ford in Nevada. I didnt price the muffler shop.

So you just live with the rusty muffler? I checked Rockauto.com and found that our muffler only costs $55 and the silencer costs only $66. And it seems no welding is needed. I'm just wondering whether anybody has replaced their exhaust system behind the cat.

[96wWindstar180K]

lidation
I asked the guys at Merlins to look at it while they were under there replacing the flex pipe and they said everything was in good shape. Nothing rusting through. Its just surface rust. Now I dont know about yours. Even the tail pie and resonator were fine. They actually sraightend the tailpipe for me because my daughter backed into aflower box and bent the tailpipe a little.

[wiswind]

I also have my original exhaust system.....except a new "Y" pipe....due to rattling internals in a catalyitic converter.
I have surface rust on my muffler...etc...but still strong.

From what I have read.....the whole exhaust system, from the back side of the flex pipe, to the tail pipe (including muffler) is all 1 unit.
To replace, you buy the individual parts....and put them together.
I would not worry about the system unless you develop holes in it.