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94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | Exhaust clamp rusted/leaking In for a/c service today and remembered to ask about my exhaust leak sound. Tech noticed the clamp was rusted and cracked and was probably the cause of the leak. He requested a fax of the complete exhaust layout complete with part #'s. Located the clamp part # and I'm scheduled for another service for next Wednesday, 5/22. I'm wondering if the clamp is just a generic clamp that can be replaced at home? 1st image is the cracked clamp, passenger side, 2nd image is clamp on drivers side. Edited by 94rover 5/14/2013 2:01 PM (IMG_20130514_134105.jpg) (IMG_20130514_134136.jpg) Attachments ---------------- IMG_20130514_134105.jpg (35KB - 13 downloads) IMG_20130514_134136.jpg (34KB - 0 downloads) | ||
#213935 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | Re: Exhaust clamp rusted/leaking Are the bolts intact? They often rust through and break allowing the exhaust joint to loosen. The clamp is easy and cheap to get, but you need to section the pipe to get it over the flange. It would be better to just weld the damaged clamp in situ. I have a broken clamp and bolts that are gone, but no exhaust leak so far. | ||
#213938 - in reply to #213935 | |||
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94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | Re: Exhaust clamp rusted/leaking 1 bolt appears to be "hanging on" and it looks almost too difficult to weld in position without a steady hand. Hmm, maybe I'll keep my standing appointment and trust that the repair will be non difficilis... Stay tuned. | ||
#213942 - in reply to #213938 | |||
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Roly Elite Veteran Date registered: Apr 2006 Location: Australia Vehicle(s): 1999 G500 Posts: 661 | Re: Exhaust clamp rusted/leaking I've had limited success with repairing the exhaust clamps. On the rear cross pipe I replaced the bolts, cleaned the clamps which were solid, and retightened. All good to date. On the downpipes to cat section, the clamps were rusted through so broke when they were removed. I cut off the clamps, got a section of straight pipe welded to the cat and slid it over new downpipes with a D clamp. This has worked well also. It's always worth trying a repair before throwing it out. Maintenance vs capex | ||
#213943 - in reply to #213942 | |||
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hipine Date registered: Jul 2006 Location: US, CO, Bailey Vehicle(s): 460 1980 280GE w. 617A | RE: Exhaust clamp rusted/leaking generic clamps are available of a 2-piece design that don't require cutting the pipe. Any general muffler shop should be familiar with the "split flanges" on page 10. http://www.nickson.com/newcatalogs/__Retail_Contents_SM-1.pdf -Dave G. | ||
#213959 - in reply to #213935 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | RE: Exhaust clamp rusted/leaking Thanks for the link on the split flanges Dave. I have a solid replacement flange sitting on my workbench trying to figure out how I might be able to make it work without cutting the pipe. I'll order up a box and post back with results once I get some installed. | ||
#213969 - in reply to #213935 | |||
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94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | RE: Exhaust clamp rusted/leaking Thanks Dave. I poked around some more today and removed some of the rust. (IMG_20130515_101230.jpg) Attachments ---------------- IMG_20130515_101230.jpg (35KB - 14 downloads) | ||
#213977 - in reply to #213935 | |||
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94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | RE: Exhaust clamp rusted/leaking There also appears to be more corrosion underneath the flange... (IMG_20130515_101230 (1).jpg) Attachments ---------------- IMG_20130515_101230 (1).jpg (34KB - 5 downloads) | ||
#213978 - in reply to #213935 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | RE: Exhaust clamp rusted/leaking triple post Edited by otiswesty 5/16/2013 12:10 PM | ||
#213993 - in reply to #213969 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | RE: Exhaust clamp rusted/leaking err Edited by otiswesty 5/16/2013 12:10 PM | ||
#213994 - in reply to #213969 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | RE: Exhaust clamp rusted/leaking The pipe going into my muffler is a tight 2 1/4 inch, whereas the exhaust clamp I have is a tight 2 inches. I ordered a pair of each of the 3 available sizes and will see which fit best. Only $6 each. (2inch.JPG) (2quarter.JPG) Attachments ---------------- 2inch.JPG (131KB - 0 downloads) 2quarter.JPG (118KB - 0 downloads) | ||
#213995 - in reply to #213969 | |||
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94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | RE: Exhaust clamp rusted/leaking Last Saturday while planning out my day I recalled the shop that installed the y-pipe on my Classic way back in 99 and decided to visit and get a quote on repairing my exhaust. Glad I did. The shop owners remembered me and were more than thrilled to "make the simple fix" Only took 20 minutes and didn't cost me more than an hour conversation. (IMG_20130518_114301.jpg) (IMG_20130518_114502.jpg) Attachments ---------------- IMG_20130518_114301.jpg (237KB - 0 downloads) IMG_20130518_114502.jpg (296KB - 0 downloads) | ||
#214130 - in reply to #213935 | |||
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fernweh Date registered: Apr 2006 Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa | RE: Exhaust clamp rusted/leaking Sorry about all the trouble with the rusted out resonator pipe / clamp. Our new stainless steel replacement resonator pipes also go very well with those nice aluminum offroad steps http://www.g-wagenaccessories.com/products/exhaust.htm Karl PS what a shameless plug.... (Resonator Exhaust Pipe Kit.jpg) (OEM style muffler connection.jpg) (OEM type catalyst connection.jpg) Attachments ---------------- Resonator Exhaust Pipe Kit.jpg (51KB - 0 downloads) OEM style muffler connection.jpg (91KB - 0 downloads) OEM type catalyst connection.jpg (68KB - 0 downloads) | ||
#214135 - in reply to #213935 | |||
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94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | Re: Exhaust clamp rusted/leaking I wanted very much to order the resonator exhaust pipe kit instead of repairing my current set up. The day will come. | ||
#214136 - in reply to #214135 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | Re: Exhaust clamp rusted/leaking This is a great example of how the MBUSA Gwagens are superior due to availabilty of both aftermarket and dealer support. If only Karl would make replacement exhaust pieces for the early G500, I would be all set. Good thing I am a resourceful fellow and manage to get along on my own. Edited by otiswesty 5/22/2013 12:07 AM | ||
#214140 - in reply to #214136 | |||
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fernweh Date registered: Apr 2006 Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa | Re: Exhaust clamp rusted/leaking otiswesty - 5/21/2013 9:06 PM This is a great example of how the MBUSA Gwagens are superior due to availabilty of both aftermarket and dealer support. If only Karl would make replacement exhaust pieces for the early G500, I would be all set. Good thing I am a resourceful fellow and manage to get along on my own. :dunce: Sorry Charlie, I fabricated those stainless steel pipes just for you to use, but you had to go back to the future and buy that 1999 G-wagen Karl | ||
#214147 - in reply to #214140 | |||
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AlanMcR Expert Date registered: Apr 2006 Location: US, CA, Los Altos Vehicle(s): G300DT E300DT 230SL Posts: 3500 | Re: Exhaust clamp rusted/leaking fernweh - 5/22/2013 6:23 AM Sorry Charlie, I fabricated those stainless steel pipes just for you to use, but you had to go back to the future and buy that 1999 G-wagen Karl Hey! You should know that old dudes / old Gs rule. Who needs all that new stuff? | ||
#214155 - in reply to #214147 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | Re: Exhaust clamp rusted/leaking Who is Charlie? | ||
#214158 - in reply to #214147 | |||
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94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | Re: Exhaust clamp rusted/leaking Anyone on P3 with Karls resonator pipe installed (including Karl) and care to share a pic of the kit on your G? | ||
#214173 - in reply to #214158 | |||
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fernweh Date registered: Apr 2006 Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa | Re: Exhaust clamp rusted/leaking otiswesty - 5/22/2013 11:51 AM Who is Charlie? Don't you remember Charlie Tuna? .....Sorry Charlie,..... Must have been before your time Below you find the before and after images, plus an extra bonus: How does the catalyst looks inside....Tic welding 101 Karl Edited by fernweh 5/22/2013 10:01 PM (Before.JPG) (After.JPG) (Split Catalyst.JPG) (other part.JPG) ($1700 saved.JPG) Attachments ---------------- Before.JPG (117KB - 0 downloads) After.JPG (96KB - 0 downloads) Split Catalyst.JPG (239KB - 0 downloads) other part.JPG (247KB - 0 downloads) $1700 saved.JPG (206KB - 0 downloads) | ||
#214174 - in reply to #214158 | |||
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