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6th Generation (1988-1992) Specific discussion of the AE92

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Old 01-10-2011, 03:12 AM   #1 (permalink)
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Leaking rear muffler? A cheap way of fixing it.

The connection from the rear muffler and the middle pipe/muffler has a flange vith two bolts, just above the rear axle. It seems that this is the part of the muffler that breaks apart first (rust!). If the rest of the exhaust system is in good condition I suggest replacing the faulty flange with a pipe and a clamp.
You'll need a two-step adapter pipe which has a diameter of 48-49mm on one side and 44-45mm on the other (picture #4). These are inexpensive (< $10) and can be found at most shops that sells mufflers.
First: remove the rear muffler and the middle tube/muffler from the vehicle. After that: just remove the flange and everything that has to do with it (picture #6). A hammer and a big screwdriver will probably be enough. Cut of the welding seam with a grinder from the muffler pipe (picture #8). When this is done you'll have two ends - but with different diameters (pictures #5 and #7)
Weld on the part with the 44-45mm diameter on the pipe that is sticking up from the middle pipe/muffler. It must be airtight so it's quite important that it's done with precision and it must be not be angled different then the rest of the pipe. Cut two notches at the end. Make sure it'll fit onto the other pipe. If not: use a grinder to remove some metal until it does.
Time to reinstall everything (pinctures #2 and #3). Use a click of paste made for exhaust systems. Clamp on (picture #1). Start engine and check for leaks.
I suggest to use some rust-proof paint on the welding seam.
Ready to go!









Last edited by nizzehult; 01-10-2011 at 03:51 AM.
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Old 01-10-2011, 05:42 PM   #2 (permalink)
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or move somewhere where rust isn't an issue....
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Old 01-15-2011, 11:19 PM   #3 (permalink)
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id just take the muffler off, it makes my car sound kool like a mustang... lol kidding, but yeah nice write up man, i dont get that here in southern california, mine is still kicking new, like it came outta the showroom yesterday.
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