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Old 05-18-2014, 12:44 PM   #1
maw230
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Default Obvious exhaust leak. Not sure what's next.

Hey guys,
I'm doing some work on my transmission, so I had to drop the exhaust. Taking it apart was a giant rust filled mess and now that it's back together it seems as if the connection between the 2 cats (i think) just won't fit back together properly. When I start the car there is a massive exhaust leak.

It was suggested in my transmission thread that something was holding one of the pipes back, but that doesn't appear to be the case. They are back together just as they came off.

The big difference this time is that I had to scrape off A LOT of rusted gasket/metal to remove the old gasket and I'm wondering if some of the exhaust metal was removed. Still I don't think that would be enough to cause the large gap.

I'm out of ideas besides comparing it side by side with a newer exhaust.. Which reminds me I can go check my 2002 OBS and see what it looks like. Anyway, here are some pics.

This one shows the gap between the two and the fact that the springs are compressed as far as they will go.








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Old 05-18-2014, 02:51 PM   #2
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doesn't look like it's sealing up completely those bolts look odd
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Old 05-18-2014, 03:12 PM   #3
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Quote:
Originally Posted by roccotrapani View Post
doesn't look like it's sealing up completely those bolts look odd
Bolts look fine.


Are you sure it's supposed to be a donut gasket? And if so is the one your using the right size? You should not be able to see any of that gasket once they are fitted together.
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Old 05-18-2014, 04:00 PM   #4
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Originally Posted by Reese View Post

Bolts look fine.

Are you sure it's supposed to be a donut gasket? And if so is the one your using the right size? You should not be able to see any of that gasket once they are fitted together.
Hopefully I kept the receipt for the part. Got it from the dealer. Pretty sure that is the same gasket I took off, but there wasn't much of it left.
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Old 05-18-2014, 05:26 PM   #5
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Quote:
Originally Posted by maw230 View Post
Hopefully I kept the receipt for the part. Got it from the dealer. Pretty sure that is the same gasket I took off, but there wasn't much of it left.
Maybe it broke off inside? The 1st pic looks like there might be something inside the pipe?
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Old 05-18-2014, 05:28 PM   #6
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yea I agree the gasket is looking too big when it's all tightened up you should only be able to see a small amount of that gasket.
the flanges don't look too bad
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Old 05-19-2014, 10:37 AM   #7
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Last time I had this part of my exhaust apart I had to do a ton of chipping and scraping to the inside diameter of the mating surfaces. The gasket material is so hard that sometimes it blends in with the metal. Take a junky flathead screwdriver or a small chisel and see if you can't break away some material. It's doesn't seem too likely that the dealership would give you the wrong gasket since you have to tell them your VIN to buy a freaking lug nut from them. It's so they can't mess up and give the wrong part, right? haha
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Old 05-19-2014, 04:19 PM   #8
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Quote:
Originally Posted by roccotrapani View Post
yea I agree the gasket is looking too big when it's all tightened up you should only be able to see a small amount of that gasket.
the flanges don't look too bad
If I saw any less of that gasket then the two ends would barely touch each other... Does that mean it's sticking too far down onto the front pipe? The part number is 44022aa063 and I'm currently trying to see if it's the right one for my 05 OBS. Should be part 4 in this list, but this website is confusing.

https://www.subarugenuineparts.com/oe_parts_cat.html
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Old 05-19-2014, 11:14 PM   #9
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they make a spring bolt kit with 2 different bolt lengths. You need the shorter ones. You also need to clean that back pipe more that thing is at least an inch from sealing. I'd go aftermarket on the spring kit
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Old 05-20-2014, 05:41 PM   #10
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Originally Posted by Subie-Lifer View Post
they make a spring bolt kit with 2 different bolt lengths. You need the shorter ones. You also need to clean that back pipe more that thing is at least an inch from sealing. I'd go aftermarket on the spring kit
Thanks. Where is a good retailer for the spring kit?
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Old 05-21-2014, 05:46 AM   #11
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I've always used the OE donut gasket and OE spring bolts for mating the cat pipe to the mid pipe.
As others mentioned, make sure that it's all clear of material and nothing is being doubled up on.
Aside from that, when you tightened these, do a little bit while alternating to keep the pressure even and the pipes lined up.
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Old 06-13-2014, 09:19 PM   #12
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So this is the other end. When I'm scraping it off if seems like a lot of metal is coming with it.

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Old 06-14-2014, 12:26 AM   #13
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The inside of that pipe still has some of the gasket in it
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Old 06-14-2014, 03:23 AM   #14
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Originally Posted by EdHilario View Post
The inside of that pipe still has some of the gasket in it
Yeah I'm chipping away at it, but it feels and looks like I'm chipping away metal as well.
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Old 06-14-2014, 10:52 AM   #15
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You won't chip away any metal, just a thin layer of rust between the gasket and pipe. Scrape away, you aren't going to hurt it
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Old 06-14-2014, 11:54 AM   #16
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Some? You have most of the old gasket left

The metal that is chipping away is gasket material.

Stick a flat blade screwdriver into the back of the bottom of the gasket and pry from the top. It will pop out mostly intact.
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Old 06-14-2014, 12:35 PM   #17
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Just poke the gasket out of there. Likely to come out as a whole piece with gentle prying back and forth.
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Old 06-16-2014, 09:56 AM   #18
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Haha you guys were definitely correct. I got it all out of there. I was confused about what was gasket and what was pipe.

Put it back together and there is still a miniscule leak that I don't want mess with right now.
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Old 06-16-2014, 01:16 PM   #19
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They make junk you can spread on their like putty to seal it up. Or it might go away on it's own if it is just a little leak. I wouldn't worry about it being that far back. If it was a exhaust manifold gasket I would tell you to take care of it right away
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Old 06-26-2014, 08:14 PM   #20
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Well I think after some extended driving the leak has sealed. Thanks for the help guys. I will keep the putty in mind for the inevitable next time.
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Old 06-26-2014, 09:28 PM   #21
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Good job bud
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