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DIY Y-Pipe Repair

 
  #1  
Old 11-08-2013, 08:07 PM
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DIY Y-Pipe Repair

Seems at one time or another many 6.0 owners experience exhaust smell in the cab or a loss of boost attributed to cracked bellows in the Y-Pipe.

Currently with discounts a new Y-Pipe can be sourced for under $225 and a solid Y-Pipe from aftermarket vendors can be had for roughly $450.

Another option is to repair the Y-Pipe, but instead use heavy duty turbo purposed flex couplings, roughly $60 and labor.

Here is today's candidate.



I had some free time at work so I figured to do a quick run through of a Y-Pipe repair.

I already have a jig made, which means to get started on your own you'll need to fashion something similar. Basically you want the Y-pipe in a neutral position and rigid while the couplers are welded to prevent tweaking or warping.



Once that is set, cut out the damaged pieces. In this case the exposed bellow style was cracked, but replacing both seems wise. Cut just after the factory welds:



Clean all burrs and prep the ends for welding. It might take a few trials to fit everything together.







And a word of caution about the flex couplings. You want the heavy duty 3 layer joints. Spiral innner layer, bellow middle layer and braided outer...





Whereas many seem to use these, which are barely suitable for a Geo Metro...





Tack everything together, double and triple check then lay your beads...




Here are the OEM flex joints cut in half. Bascially there are both the same, except one has the extra layer of braiding. The key difference versus Vibrant style HD joints is the OEM has the solid inner tube which actually makes them rather rigid. More for expansion I would assume rather than flexing. With the solid tube you can have trapped gases and moisture.






Josh
 
  #2  
Old 11-08-2013, 08:18 PM
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I currently have a bit of a smell coming inside...thought this might be the issue.
 
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Old 11-08-2013, 08:21 PM
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Well looks like your Setup with the Jig and welder

You have a Day in the Jig LOL whats the Boss think LOL

Look like your in Business How MUCH you doing them for??
 
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Old 11-08-2013, 08:41 PM
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Originally Posted by BLADE35 View Post
Well looks like your Setup with the Jig and welder

You have a Day in the Jig LOL whats the Boss think LOL

Look like your in Business How MUCH you doing them for??
I've had the rough jig for a while, I did fine tune it the other day on a different set of pipes.

Josh
 
  #5  
Old 11-08-2013, 10:25 PM
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Excellent job!!!
 
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Old 11-08-2013, 10:53 PM
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How much are you looking to charge to do this???
 
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Old 11-09-2013, 09:50 AM
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I'll be doing this same thing soon.

Noticed a tiny leak on my new to me 6.0 when I was pullin the motor.

 
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Old 11-09-2013, 10:08 AM
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Well done,I would send mine out for this update when cleaning the turbo.
 
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Old 11-09-2013, 12:01 PM
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Josh that Geo metro one is that just single layer??

Maybe Double?
 
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Old 11-09-2013, 01:35 PM
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Originally Posted by BLADE35 View Post
Josh that Geo metro one is that just single layer??

Maybe Double?
It's double layer, but would never hold up to the turbo back pressure of a diesel.

Josh
 
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Old 11-09-2013, 01:41 PM
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I thought it was interesting that the Original flex joints were different one compared to other

I thought mine both Looked the same But IDK will have to look

What was this Ypipe out of??
 
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Old 11-09-2013, 02:43 PM
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Originally Posted by BLADE35 View Post
I thought it was interesting that the Original flex joints were different one compared to other

I thought mine both Looked the same But IDK will have to look

What was this Ypipe out of??
The driver's side has the the accordion style with braided outer. The other side of the y-pipe and the up pipe have the standard accordion.

This particular y-pipe was removed from a 2005 F550.

Josh
 
  #13  
Old 11-09-2013, 07:26 PM
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Slightly off topic... Can the Y-Pipe be removed and replaced with the cab on?
 
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Old 11-09-2013, 07:40 PM
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Originally Posted by 56fordfella View Post
Slightly off topic... Can the Y-Pipe be removed and replaced with the cab on?
Yes, you remove the turbo and then are able to lift the y-pipe out from above.

Josh
 
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Old 11-09-2013, 07:41 PM
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Originally Posted by villestrip View Post
How much are you looking to charge to do this???
PM me and we can figure something out.

Josh
 

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