07 exhaust repair

695 Views 10 Replies 5 Participants Last post by Automender12345, 1 mo ago

bluehorn14

Discussion Starter · 1 mo ago

Hey everyone,

2007 taurus

So the car was in minor scuffle, however the exhaust broke at the front.

I'm very unfamiliar with exhaust repairs. Can you guys guide me in terms of what actually broke? I can see bolts still attached in pic 4.

Money wise, what am I'm looking at if i take it into a shop? Can i junk parts to lower the cost? I appreciate the help.

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Automender12345

· #2 · 1 mo ago

Look at this post

Possible exhaust leak at flex joint 2005 3.0 OHV Vulcan

I have what sounds like an exhaust leak when I accelerate. It’s a low pitched raspy sound. I went over the exhaust pipes, cats, heat shields, O2 sensors, and checked the top of the muffler and cats for hidden leaks. Here is a shot of my flex joint. Anyone ever remove and replace it?

www.taurusclub.com

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TaurusDailyDriver

· #3 · 1 mo ago

You’ll need to either replace the third cat assembly or the cheaper route is to remove what’s left of that flex pipe and purchase a repair kit.

I did the repair kit on my old Sable and it held up for quite a while. I did have to replace the piece because they’re not the greatest quality, but it will get you back on the road cheaply. Attached is an example. There’s plenty out there. I believe I got mine from rock auto or an eBay vendor.

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bluehorn14

Discussion Starter · #4 · 1 mo ago

TaurusDailyDriver said:
You’ll need to either replace the third cat assembly or the cheaper route is to remove what’s left of that flex pipe and purchase a repair kit.

I did the repair kit on my old Sable and it held up for quite a while. I did have to replace the piece because they’re not the greatest quality, but it will get you back on the road cheaply. Attached is an example. There’s plenty out there. I believe I got mine from rock auto or an eBay vendor.

When you used the repair kit, did you have to weld? Automender above linked a post about using a clamp, but i'm not sure if we're talking about the same part.

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TaurusDailyDriver

· #5 · 1 mo ago

It can be welded or clamped. I clamped mine in my repairs.

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bluehorn14

Discussion Starter · #6 · 1 mo ago

TaurusDailyDriver said:
It can be welded or clamped. I clamped mine in my repairs.

Thanks. I'll probably go that route. In the first picture i posted, it looks like part of the exhaust that broke is still welded to the end of the tube...That would have to be removed before installing the repair kit, right? If so, how would you recommend I remove it?

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helifino

· #7 · 1 mo ago

cut it just behind the hump with a hacksaw (or if you have one, a reciprocating saw). It might be helpful to wrap some tape around it to give you a cut line

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Lisfin

· #8 · 1 mo ago

Just recently replaced mine during the fall as it was leaking and car was starting to sound like a beater. For my 07 Taurus I was quoted around $200 to replace the flex pipe at a muffler shop. I looked up and purchased a flex pipe from Amazon for $26 and had my dad weld it on as he has lots of experience as a pipe fitter.

EASYBERG Stainless Steel Flange Flex Coupling Exhaust Repair Pipe Compatible with 2000-2007 Ford Taurus 2000-2005 Mercury Sable

We removed the bolts and nuts which was the hardest part, had to cut one off as it was rusted stuck, this allowed the exhaust to drop down in the front giving more room for the next step. Than we measured and than cut the other end off. Than we bolted on new one and than had my dad butt weld it to the rear exhaust part. Thanks to him I was able to save at least $150 and now car is much much quieter and not leaking noise or exhaust anymore.

If you know someone that can weld it will save you a majority of the money compared to a shop.

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Automender12345

· #9 · 1 mo ago

Wait until you get the replacement flex connector to determine where you need to cut the original pipe. Remove the bolted connection at the Y pipe ad bolt on the new flex connector. You will have to determine if the replacement flex joint fits inside or outside of the original pipe. The band clamp is better than the crimp clamp since they don't distort the pipe and when you need to replace the flex joint again it is much easier.

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bluehorn14

Discussion Starter · #10 · 1 mo ago

Automender12345 said:
Wait until you get the replacement flex connector to determine where you need to cut the original pipe. Remove the bolted connection at the Y pipe ad bolt on the new flex connector. You will have to determine if the replacement flex joint fits inside or outside of the original pipe. The band clamp is better than the crimp clamp since they don't distort the pipe and when you need to replace the flex joint again it is much easier.

Good advice. I'm ordering the following from ebay:
Replacement Connector

With the band clamp, do you know what size approximately?
Also, I don't think this kit comes with bolts. I'm not betting on reusing the old ones...Bolts and washers from the hardware store should do it right?

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Automender12345

· #11 · 1 mo ago (Edited)

bluehorn14 said:
Good advice. I'm ordering the following from ebay:
Replacement Connector

With the band clamp, do you know what size approximately?
Also, I don't think this kit comes with bolts. I'm not betting on reusing the old ones...Bolts and washers from the hardware store should do it right?

I did mine over ten years ago and can't remember. I believe I bought it from Summit Racing. Maybe somewhere around 1.75 inch but can't remember and it is stepped one pipe wall thickness. Also I believe kits vary to have either a butt fit, inside fit and outside fit.

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