How to Repair an Exhaust Leak without Welding

How to how to replace a piece of exhaust section on a vehicle. For this I’m using a 2015 Mazda CX9 as an example, the rear Y pipe section has developed holes and needs a replacement. With holes in the exhaust, this can be a safety concern as the fumes from the exhaust can migrate inside the cabin. The exhaust may get rusted enough that does fall apart on the road, also creates hot spots on the floor or other components, and causes your vehicle to sound noisy. #OEMTools #exhaust #automotiverepair
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Tools/Supplies Needed:
-recipricating saw
-surface sander
-marker
-torch
-socket set with ratchet
-safety glasses
Procedure:
Clean up the threads on the studs from the mufflers. This will make the removal much easier, these threaded studs are welded onto the mufflers so if one does break, more work is required to repair this. Penetrating oil is applied to each of the studs to aid in the removal process.
Due to the excessive rust, I hammered on a socket. However I did find the socket does slip because the nut is too far rusted. I used vice grips instead, again it wasn’t breaking free. Moving onto the top bolt, again no luck here either.
The next best possible solution is using heat. The nut is heated up red and it still wasn’t breaking free with the vice grips. I decided to take an alternative route trying to split the nut in half with a chisel. This method eventually made the nut turn. Moving onto the nut above, after applying heat I was able to break it free with a ratchet and remove it.
Moving onto the opposite side again with the same problem the same procedure was used.
Now breaking the flange is free. This is most likely rusted together so it will take some force. I did find a gap in the flange where I was able to insert a chisel and slowly hammer the connection apart.
Match up the new y pipe. This is needed to determine where I am required to cut the midsection. A marker is used to mark the cut line, this will be about 6 to 8 inches back from the end of the pipe. I’m leaving extra material on for fitment.
I used a sawzall to cut the old pipe out. This has a metal blade, and watch on the opposite side so it doesn’t poke into anything it shouldn’t. I am also avoiding using an angle grinder as the gas tank is right here.
To remove the rubber hanger, I purchased a tool for this. This is by far the easiest method to disconnect the rubber hanger. Penetrating oil is applied to the hanger, the specialty pliers to push the steel rod through the rubber.
The new section of exhaust is put into place and I’ll determine where the final cut line is. This pipe came with an expanded inlet. Again using the sawzall, this section of pipe is cut to the appropriate size.
I used a drill with a wire wheel to help clean any rust off the exhaust so the connection would slide together. Sandpaper is another option however it does take more time. Another option is a surface prep sander which is a bit more aggressive route but works great. The same is done to the muffler flanges.
Now the gasket is installed and the pipe is put into place on the one muffler. A nut is used to hold the flange and place it so it doesn’t disconnect. After that is the opposite side.
I gave the exhaust a quick shake to ensure it was seated at the correct angle. Then an exhaust clamp is used on the slide on connection. You’ll need to pick the appropriate type which is based on the diameter of the pipe. The bottom portion of the flange is angled in such a way that it’s not hanging down and catching on anything. This will squish around the pipe, clamping the new pipe onto the old pipe.
The rubber hanger can then be installed back onto the exhaust pipe. Simply push it into place and it will expand over the flared hanger bracket.
I went around one last time to check the nuts, ensuring they are tight.
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© 4DIYers 2013
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[@BruceLyeg]

Those exhaust hanger pliers are worth their weight in gold when you need them.

[@broomad]

You need a set of Irwin rounded nut removal sockets. They work really well in this situation and so far have never let me down 👍