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Exhaust clamp rusted/leaking
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Posted 5/14/2013 1:57 PM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
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)



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Attachments IMG_20130514_134105.jpg (35KB - 13 downloads)
Attachments IMG_20130514_134136.jpg (34KB - 0 downloads)
#213935
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Author
Posted 5/14/2013 3:09 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
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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Author
Posted 5/14/2013 3:36 PM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
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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Posted 5/14/2013 4:21 PM
Roly
Elite Veteran




Date registered: Apr 2006
Location: Australia
Vehicle(s): 1999 G500
Posts: 661
500
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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Author
Posted 5/14/2013 10:35 PM
hipine



Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
5000
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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Posted 5/15/2013 11:41 AM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
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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Posted 5/15/2013 3:34 PM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
RE: Exhaust clamp rusted/leaking

Thanks Dave. I poked around some more today and removed some of the rust.







(IMG_20130515_101230.jpg)



Attachments
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Attachments IMG_20130515_101230.jpg (35KB - 14 downloads)
#213977 - in reply to #213935
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Posted 5/15/2013 3:50 PM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
RE: Exhaust clamp rusted/leaking

There also appears to be more corrosion underneath the flange...



(IMG_20130515_101230 (1).jpg)



Attachments
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Attachments IMG_20130515_101230 (1).jpg (34KB - 5 downloads)
#213978 - in reply to #213935
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Posted 5/16/2013 12:08 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
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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Posted 5/16/2013 12:09 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
RE: Exhaust clamp rusted/leaking

err

Edited by otiswesty 5/16/2013 12:10 PM
#213994 - in reply to #213969
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Posted 5/16/2013 12:09 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
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)



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Attachments 2inch.JPG (131KB - 0 downloads)
Attachments 2quarter.JPG (118KB - 0 downloads)
#213995 - in reply to #213969
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Posted 5/21/2013 10:55 AM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
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)



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Attachments IMG_20130518_114301.jpg (237KB - 0 downloads)
Attachments IMG_20130518_114502.jpg (296KB - 0 downloads)
#214130 - in reply to #213935
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Posted 5/21/2013 5:40 PM
fernweh



Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
2000
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
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Attachments Resonator Exhaust Pipe Kit.jpg (51KB - 0 downloads)
Attachments OEM style muffler connection.jpg (91KB - 0 downloads)
Attachments OEM type catalyst connection.jpg (68KB - 0 downloads)
#214135 - in reply to #213935
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Posted 5/21/2013 6:56 PM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
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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Posted 5/22/2013 12:06 AM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
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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Posted 5/22/2013 9:23 AM
fernweh



Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
2000
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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Posted 5/22/2013 12:06 PM
AlanMcR
Expert




Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
2000
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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Posted 5/22/2013 2:51 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
Re: Exhaust clamp rusted/leaking

Who is Charlie?
#214158 - in reply to #214147
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Posted 5/22/2013 8:44 PM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
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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Posted 5/22/2013 9:49 PM
fernweh



Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
2000
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
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Attachments Before.JPG (117KB - 0 downloads)
Attachments After.JPG (96KB - 0 downloads)
Attachments Split Catalyst.JPG (239KB - 0 downloads)
Attachments other part.JPG (247KB - 0 downloads)
Attachments $1700 saved.JPG (206KB - 0 downloads)
#214174 - in reply to #214158
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