ThosL Posted April 15, 2015 Share Posted April 15, 2015 I have an unpleasant exhaust noise coming out from between the cat. converter and the pipe behind it. I spent some time getting parts for the repair at Napa, etc.. There is a donut style tapered gasket there and the bolts, etc. holding in a sandwiched assembly that connects the two pipes. How tough is this job? I don't know if the bolts will come out readily and the pipes will go back together easily. How tough a job is this? Quote Link to comment Share on other sites More sharing options...
AdventureSubaru Posted April 15, 2015 Share Posted April 15, 2015 Pretty easy if it's not rusted to bits and you give yourself some space using jack stands. Before living in rust free california when in the east coast and midwest salts, I would commonly just cut the rusted bolts off with a grinder and replace them with new. They are a pain when rusted and seized up. Quote Link to comment Share on other sites More sharing options...
nipper Posted April 15, 2015 Share Posted April 15, 2015 (edited) I tried this once. Living in NY it was all rusted to bits and I paid a REAL muffler shop to deal with it. I tried but it was just a case of too much rust, too much labor and not having a torch. They fixed it in less then an hour for less then 100 bucks. Go to a custom exhaust shop for best results, not a chain shop. Some jobs are very satisfying to do yourself, some jobs are very satisfying when you pay someone else to do it. Edited April 15, 2015 by nipper Quote Link to comment Share on other sites More sharing options...
montana tom Posted April 15, 2015 Share Posted April 15, 2015 (edited) I just replaced that donut on a 99 forester and yes both bolts broke... the parts house had no trouble getting original equipment , bolts, springs & nuts. What was left of the old donut had to be chiseled off , and reassembly was no problem. Edited April 15, 2015 by montana tom Quote Link to comment Share on other sites More sharing options...
ThosL Posted April 15, 2015 Author Share Posted April 15, 2015 I don't have jack up capability or sawzall so this is likely beyond me. The Auto Zone mechanic is busy and wants $120 to do the job if I bring the parts, so I'll look around. Quote Link to comment Share on other sites More sharing options...
Rooster2 Posted April 15, 2015 Share Posted April 15, 2015 Suggest you look for a family owned muffler shop in your area that does torch off, pipe bending, and weld on new pipes and mufflers. If you find such a shop, they will be able to fix the leak for a small fee. I Just had the same thing fixed on my OBW for about $50. Don't bother going to a big muffler chain operated store. Their solution will ask you to spend $350-$500 for a complete muffler system from the cat on back to the tail pipe. You don't need to do all of that. Quote Link to comment Share on other sites More sharing options...
ThosL Posted April 17, 2015 Author Share Posted April 17, 2015 I would go to one of those if there was one around here that was reasonable, but I don't know any and I'm a pretty good researcher. A garage about an hour away charges only $70 an hour and you can bring your own parts. Quote Link to comment Share on other sites More sharing options...
montana tom Posted April 17, 2015 Share Posted April 17, 2015 If you have the donut and the 2 new bolts with springs and nuts, then this is not hard at all. Your car came with a jack to change tires so you can lift it up. Sawzall is not needed ... those old bolts will either unthread or break... worse case if the bolt heads strip before breaking then a hacksaw will cut them enough that a hammer will finish breaking them. The whole exhaust is rubber mounted it will pull away after the bolts are removed. The old donut will need to be persuaded with a screwdriver and hammer to come off, then just stick on the new donut, put in the new bolts and springs , let down the jack and your done! No $70.00 hr and 2 hr drive involved. Quote Link to comment Share on other sites More sharing options...
Rooster2 Posted April 17, 2015 Share Posted April 17, 2015 If you have the donut and the 2 new bolts with springs and nuts, then this is not hard at all. Your car came with a jack to change tires so you can lift it up. Sawzall is not needed ... those old bolts will either unthread or break... worse case if the bolt heads strip before breaking then a hacksaw will cut them enough that a hammer will finish breaking them. The whole exhaust is rubber mounted it will pull away after the bolts are removed. The old donut will need to be persuaded with a screwdriver and hammer to come off, then just stick on the new donut, put in the new bolts and springs , let down the jack and your done! No $70.00 hr and 2 hr drive involved. +1 on this advise. I would follow this advise. Quote Link to comment Share on other sites More sharing options...
ThosL Posted April 17, 2015 Author Share Posted April 17, 2015 OK, thanks. I may give it a try. Unfortunately the OE jack is pretty chintzy, so it got damaged when the car fell over when jacked up. I do have a jack in storage though. Quote Link to comment Share on other sites More sharing options...
nipper Posted April 17, 2015 Share Posted April 17, 2015 OK, thanks. I may give it a try. Unfortunately the OE jack is pretty chintzy, so it got damaged when the car fell over when jacked up. I do have a jack in storage though. NONONONONONONO nVEVER use the oe jack except for chainging a tire, and even then be careful. I used ramps last time I tried doing this. Quote Link to comment Share on other sites More sharing options...
ThosL Posted May 17, 2015 Author Share Posted May 17, 2015 So I had the local Hispanic amigos look at this issue today; the main guy is coming back from Columbia on Monday but he said he would do the job. So it was the leak between the cat converter and the pipe going back. Once he got the parts separated, the Napa donut gasket became obviously too big but he said he would try to sandwich it in with the split flange. It was relatively easy, price $60. We still have one of the Y pipe gaskets that is leaking he had no more time today for that. Quote Link to comment Share on other sites More sharing options...
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