1996 Mercury Sable Exhaust System

[Hookmaster]

In July or August I put on a new muffler and the short tailpipe section that goes over the rear axle. Now the beginning of the pipe just after the catalytic converter is rusting out. What are the chances I can save the parts I put on last summer? My daughter comes home from school in a couple of weeks and I want to do the repair then so need to get parts soon. Last time I bought the muffler locally and the short section of pipe online. Hopefuly I can at least save the muffler.

[Macgyver55]

After that amount of time you should be able to get them off. It may take some work but I'd start by cutting off the pipe in front of the muffler and leaving enough to grab onto and work with. Some heat may be needed but it should be doable. You'll probably a need a pipe expander too so you can get it to fit back on to the new pipe.

[Scott K]

To be honest, a muffler shop would install that pipe for little or nothing. More then likely less then $100 parts and labor. Not sure if messing with it on your back, trying to get that pipe out of there without the proper tools, will be worth it for a $100??

I would call one and get a price before messing with it yourself.

[delcecchi]

As an old time amateur repair guy, I will tell you that I did an exhaust procedure ONCE, when I was young and stupid. It is now on my list of "don't do that"

I didn't find laying on my back with rust falling in my face all that much fun, and it didn't save that much money. A guy with a torch and air tools can do it like 10 or 20 times faster.

[Macgyver55]

Well, I'll readily admit its no fun, but as an old professional repair guy who's done his share of exhaust work and recently finished putting 2 daughters through college I would imagine Hookmasters motivation is to save a few bucks where he can. I agree he could get it done somewhere but depending on the parts needed, (one or both of the pictured) I think he is looking at quite a bit more than 100 bucks for parts and labor. It would also depend somewhat on what the rest of the vehicle is like as to what it is worth to him to spend on it. Also, some repair shops wont try to reuse or save an old part and you end up replacing good parts and dont save much in the end.

[Hookmaster]

Macgyver55, those are the pipes I need. I replaced the smaller one plus the muffler so I would have to cut the smaller one off the muffler. When I got my first vehicle in the late 70s, I had to replace the muffler on that and saved the pipes. Talk about bull work with no power tools and the rust in the eyes. I vowed never to do exhaust work again. Well now I have plenty of tools, eye protection, mechanics gloves (no more bloody knuckles) and I bought a compressor last summer so I have air power. To cut off the old pipes last summer, I bought a small Dremel cutting wheel and attached it to my RotoZip. Boy does that thing cut. Yep, my daughter is in college and my son will be in 2 years so I am doing more of the car stuff that isn't to complicated. Last summer on my 2004 Silverado, I put in my first water pump and the position sensor in the transfer case. It saves a lot. I enjoy doing the repairs I can. The times I helped my dad as a kid are paying off. He grew up on a farm and could repair most anything. This board has also been key to provide the right information to help on some of the repairs too. Thanks for the info. I will try to post how it goes.

[Hookmaster]

The flex pipe is what is rusted out. I know it attaches to the catalytic section by a couple of bolts. Will I be able to get them off without a torch? Does the new flex pipe come with new bolts? I know I have to buy a gasket separately.

[Macgyver55]

OOhh not a cheap pipe! Shows $124 (list) at Napa, but there are probably cheaper ones available.

I dont remember if they have welded studs or just regular bolts. If you are lucky they are bolts, if not you may have to heat them, or if you have no other choice cut them off , drill them out and use new bolts. Getting the pipe off the end will be the biggest task. Maybe the Roto disk will help you there.

[Hookmaster]

I did this repair on Saturday. The rusted out part was where the flex pipe joins the resonator. Everything went fine except I couldn't save the muffler or the crossover pipe so I had to run to the store to get another muffler. I should have bought another muffler when I got the other parts and just retured it if I didn't need it. The flex pipe bolts were a little rusted but came of easily with a little muscle and some air power. Getting these off was my biggest concern. The most difficult thing was getting the car high enough to work on the flex pipe area of the car. I have some sort of polyethylene? ramps from the auto parts store. Does anyone make ramps that are higher? I know I saved about $150-200 doing it myself.

[Macgyver55]

I have some sort of polyethylene? ramps from the auto parts store. Does anyone make ramps that are higher? I know I saved about $150-200 doing it myself.

Not a bad savings for a Saturday afternoon! You saved enough to pay for some college credits for sure.

Other than "Race Ramps" that are over 200 bucks, I've not seen ramps much over 8 to 9 inches. More than that and they are generally too high to get under most newer cars for sure and they tend to slip ahead as you go up due to the steep angle. The race ramps are longer than most so not as steep, but pretty spendy I think!

[Hookmaster]

I had to drive onto a couple of 2X4s with the rear wheel so I could get the ramp under the car. The savings almost paid for my daughter's books for this semester.