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Guest Message by DevFuse

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Exhaust / Muffler Rust

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6 replies to this topic

#1 JonnieBlue


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Posted 23 March 2004 - 04:42 PM

Okay, 1986 Xt-GL Coupe non-turbo
Right at the muffler / exhaust pipe connection where that 'u-bend with two bolts' joint is completely rusted out. As in the front of the muffler to out is completely disconnected. What is the best way to go about fixing this without spending tons of money? I dont have welding or fab equipment available, so unless is really minor, a homemade solution may not be possible. Also, theres a lot of loose junk (rusted exhausted pipe chips i assume) inside the muffler, whats the best way to get it out, or is shaking it out the only way?

-------(tail pipe)--| muffler | ________
-------(tail pipe)--|_muffler|
the rusted out joint thing ... /|\ there

Thanks in advance


#2 thealleyboy


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Posted 23 March 2004 - 06:33 PM


I'll assume that you want to keep the system "original" for e-check inspections etc.

If you want a long-term solution, you should consider dropping the exahaust at the Y pipe. You can then dissasemble, and possibly reuse some of the sections.

You can also fabricate something (to tie the corroded section back together) much easier when the parts are off the car. The area that you are referring to has a gentle curve, so a straight piece probably wont work. You'll need a "universal" curved section, or flex pipe to maintain the original shape.

When you bolt it all back together, use all new fasteners and clamps. You'll be glad you did next time you are working on the exhast system.

good luck, John

#3 bushbasher


    exhaust fume addict

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Posted 24 March 2004 - 12:06 AM

if the pipe has broken right at the flange at the muffler so that there would be nothing to bolt to on the muffler end, you can splice in a smaller pipe inside the tube and muffler and use muffler clamps (the u-bolt things) to try and hold it there, which is going to add restriction and be a possibly loose fit on the muffler or you could find another muffler, the stock one is junk anyways and it sounds like its full of crap anyways. You can get them pretty cheap, (a cherry bomb turbo muffler is like 40bucks cdn at the local place) and adapt the new one on with muffler clamps and exhaust pipe size adapters, which should be able to find at the local car parts place.

#4 DerFahrer


    Formerly subyluvr2212

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Posted 24 March 2004 - 12:09 PM

Can you just get an rust-free muffler assembly (from tailpipe to axleback) from a junkyard and bolt it right up?

#5 JonnieBlue


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Posted 24 March 2004 - 07:53 PM

Will someone tell me whether the drawing i put in the origional post is really the stock muffler??
I just got back from the parts store, and there "stock muffler" for my car is COMPLETELY different - The metal hangar arms that go through the rubber hangers are in very different spots, so im wondering if their idea of 'stock' is skewed, or is my current muffler not stock.

My current muffler has one pipe in, two pipes out (refer to drawing) and they said there arent any mufflers like that.

Im gonna try ( key word there is try) to hang this new one wihtout gettin it too dirty, or they wont let me return it, but please let me know on the stock vs not-stock issue, or if any other XT owners have experienced this, how did you hang it?

Thanks Again,

#6 Partsman


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Posted 24 March 2004 - 08:39 PM

Looking in my exhaust catalog, that drawing is exactly what you should have for 86-90 XT 1.8l. A "cheap" NAPA muffler is part# 18494 - $37.29 or so, plus (maybe) a new 2" clamp - part# 7335335 - $1.09 or so.

I think you got hosed by a parts guy who doesn't know what an XT is, and thinks you have a generic sub coupe. They make all kinds of muffler inlet/outlet combinations for different cars!

#7 JonnieBlue


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Posted 25 March 2004 - 12:23 AM

Thanks guys! :clap: Once again, the board rocks :headbang: !! Yeah, them local part store guys musta not known what they were talkin about. They told me that the one they gave me WAS stock, so i must not know whats goin on, or must not have the stock. So i brought in the muffler, put it on the counter, and said gimme one of these. They stood there scratchin there rump roast, and eventually tried to look it up and said they werent any made like that (1 pipe in, 2 out). Im like WTF?!? :banghead: So i got my money back (twice - they sold me 2 different ones, saying they had to be it) and now im goin to NAPA.

Partsman: I looked up that part on the NAPA website, no picture, so i guess ill take your word on that one and head in to NAPA tomorrow morning see if they have it, or if it needs to be ordered. Thanks again!


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