Exhaust leak worse than first thought.Flanged is rusted through and bolt broke off.So need to take exhaust manifold off and get bolt out. How can I repair and re-seal the flange? One of the cats is there and really do not want to have to replace that.

 

Here's what my Dad and I did on my Dakota when we had a situation almost identical to yours.

Just cut off whatever is left of the rusted flange, and put on a SPLIT FLANGE. It comes in 2 halves and bolts over the now-flangeless pipe and will act as the new flange.

We went to a local auto parts store and bought a Walker brand flange, it seemed to have the best design compared to the other split flanges we looked at.

If you live in an area where they put salt on the roads, I suggest you coat your split flange with something (we used VHT high-temp clear spraypaint) and also be sure to get stainless steel bolts, washers and nuts to put it together, so you can take it off if you need to.

 

Do you remember size or part number you used.

 

If you have the cash just take it to muffler shop and have them fix it I dont do muffler or piping that is one thing I will pay to get done.

Im Mr DIY but not that

I must admit I paid out $900 for a compleat exaust replacment new everything cat muff and pipes in 08.

 

No, you're mr.crap poster. If you don't have anything constructive to say, why post? You do this in EVERY thread.

As Priceman14 said, you need a split flange. Around $14-16. Y-pipe for our trucks is 2" so you would need a DORMAN-31867 (don't know if it's universal for American side, but that's the number through our shops book).

Get a small cut off tool in there, cut the ears off the Y-pipe, then put this one around it with some nuts and bolts. I'll guarantee you it's quite a job unless you drop the Y-pipe. If you can get it up on jack stands, get the other side off, o2 sensor connectors, and the y-pipe to cat flange out, you can drop it out of the truck and do it on the ground/bench, it will save you A LOT of headache.

 

Vi ste tako lijepo and i mean it

 

lighten up (Xxaler) mmguy18 knows I jest at times be cool

 

98 DakAz Got more time than money. Although you are right exhaust can be a pain . Thanks Xxaler for the size and part number. Checked Rockauto and they had the Walker brand for $9.80. Still going to remove Exhaust manifold . With the body lift on my truck I do have some room to work with.

So the plan is to unbolt the pipe, remove the manifolds. Then clean everything up, new gaskets. new flange and bolt everything back together

 

I think you have that backwards more money that time at this time I have both.

What I’m saying is this a good muffler shop could cut this bad section out in the truck and weld a new section in for you not have them do everything just the needed section.

Get an estimate from a shop or two you may get lucky and not cost all that much at all.

A good shop will be able to do it with ease that is there specialty

The main problem is finding a good shop that doesn’t want to charge you an arm and a leg for simple work and is good at his work if they just want to replace the bad part not fix the bad section then they are not a good shop just hacks looking to empty your bank account.

 

Want give me some lol.