Welded exhaust system problem
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Welded exhaust system problem
27 Mar 06
I have a leaking "Flex Pipe" on my 1993 Aerostar with 89000 miles that needs to be replaced. I can get one on line very reasonably.
I checked under the Aerostar to verify length etc. and found that the Flex pipe is welded to the front of the muffler and the tail pipe is welded to the back of the muffler. Is that normal? Did Ford weld all these parts together during manufacture? I remember having a dealer put a new muffler on my van in 1994 (under warranty) when it was only a year old. I did not watch him do it so I'm not sure if it was welded then or if that's the normal factory way of installing the components. I haven't had any other problems except for the heat shields rotting away. I really did not want to replace everything from the flex pipe back. Can someone please tell me how Ford installed the exhaust?
Thanks,
Keats
Arizona
:
I have a leaking "Flex Pipe" on my 1993 Aerostar with 89000 miles that needs to be replaced. I can get one on line very reasonably.
I checked under the Aerostar to verify length etc. and found that the Flex pipe is welded to the front of the muffler and the tail pipe is welded to the back of the muffler. Is that normal? Did Ford weld all these parts together during manufacture? I remember having a dealer put a new muffler on my van in 1994 (under warranty) when it was only a year old. I did not watch him do it so I'm not sure if it was welded then or if that's the normal factory way of installing the components. I haven't had any other problems except for the heat shields rotting away. I really did not want to replace everything from the flex pipe back. Can someone please tell me how Ford installed the exhaust?
Thanks,
Keats
Arizona
:
Former ******
Joined: Nov 2004
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From: Salt Lake City, Utah
The exact what it was originally installed is less critical. The flex is normally behind the cats, ahead of the muffler. I believe they are welded. Not all of the Aerostars I've seen in wrecking yards had flex pipes, but if they don't the manifolds crack.
Post Fiend
Joined: Apr 2005
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From: Washington state
all welded from the factory except the front bolt flange flex to back cat and joints from headers to Y pipe
cut with exhaust pipe cutter or cutoff wheel portable grinder....torch leaves melt ***** of steel which have to be removed....
put back together by cutting to fit and welding with MIG wire feed or using outside diameter couplers and clamps
don't buy the cheapy eBay flex pipes, will only last 1-2 years and burn out again....but a true stainless steel mesh with stainless steel flex inside $50-$75, example Maremont 329151
cut with exhaust pipe cutter or cutoff wheel portable grinder....torch leaves melt ***** of steel which have to be removed....
put back together by cutting to fit and welding with MIG wire feed or using outside diameter couplers and clamps
don't buy the cheapy eBay flex pipes, will only last 1-2 years and burn out again....but a true stainless steel mesh with stainless steel flex inside $50-$75, example Maremont 329151
Post Fiend
Joined: Apr 2005
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From: Washington state
the clamped systems just rust together in 10-20k miles and won't come apart because of the high temps that exhaust systems run at today....welds never leak and take far less human assembly labor...human time is money lost in the auto industry
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Just took a rotted-out flex pipe off my '95 and replaced it with a nearly new flex pipe from a friends' dead Aero (tranny problem with lucky timing for me...) Don't have a welder or torch, so I did the hacksaw thing. Not the most fun thing, but for $5 in U-bolts and a connector I have a much quieter exhaust. And yeah, it'll be rusted together in a year but I'll never need to replace it again in the van's life.
But 96_4wdr is right about the manufacturers, they'd kill for 5 cents in material or labor savings per vehicle, so when they can receive a two-piece welded exhaust system from a supplier and install it in 15 seconds, they will. Your repair convenience is 150,000 miles in the future, so they'll take the savings now, times thousands of vehicles per year, because you probably won't complain much about a 10 year old van's repair difficulty.
But 96_4wdr is right about the manufacturers, they'd kill for 5 cents in material or labor savings per vehicle, so when they can receive a two-piece welded exhaust system from a supplier and install it in 15 seconds, they will. Your repair convenience is 150,000 miles in the future, so they'll take the savings now, times thousands of vehicles per year, because you probably won't complain much about a 10 year old van's repair difficulty.
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Yea, I agree. Every penny counts to them.
I have an air cutter that should help cut the pipe. Looks like I'll buy some clamps and piece it together . I expect to get another few years out of the 93 cause it's only got 89K on it now. If need be, I'll just do another flex pipe when the time comes. For now, I just want to keep her running well.
Keats
I have an air cutter that should help cut the pipe. Looks like I'll buy some clamps and piece it together . I expect to get another few years out of the 93 cause it's only got 89K on it now. If need be, I'll just do another flex pipe when the time comes. For now, I just want to keep her running well.
Keats
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Former ******
Joined: Nov 2004
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From: Salt Lake City, Utah
on that flex, if you go to bearriverconverters.com, you can get better and cheaper flex than maramont.
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