Hello. Several months ago the exhaust system on my '93 245 literally started falling apart. I had to quit driving the car a week ago when the inlet connection to the last muffler let go and the pipe started dragging the ground. I bought the turbo exhaust parts from FCP Groton, and the replacement process generally went well until I started the car before tightening everything up and found that there was a major leak at the flange connection at the inlet of the catalytic converter. This car was from Boston originally, and the nuts holding the flange together aren't even distinguishable as separate parts anymore.

I see 4 options:

1. Bite the bullet and replace the downpipe and catalytic converter.

2. Cut the horizontal part of the downpart just before the cat flange, find a used downpipe, cut the same length off, and splice in this piece with a new cat.

3. Cut and replace the cat flange bolts.

4. Give up and take the car to a muffler shop.

Option 3 sounds the most appealing, but armed with only a hacksaw I'm not sure if I can do it or not. Even if I can cut through, I'm not sure I'll be able to remove the remains of the bolts. My experience with repair shops of any kind here in Atlanta is that they usually don't do a particularly good job and often break something else in the process.

If anyone has suggestions or advice I'd love to hear it. Thanks,

Eric
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Eric

Hey Eric,
I just performed option #3 on my own 240 a few weeks ago. I bought a new Cat from IPD and wanted to install it myself but realized that the flange bolts are not going to loosen out. I used a hand held electric grinder (Makita?) to grind the heads off the bolts until the cat fell off. Just make sure you have a fresh new grinder wheel on the tool before you start. A new wheel cuts so fast it minimizes the time you will spend working upside down under the car.

Alex Samson
Los Angeles

Eric,

A 93 in your climate should not be needing a new downpipe because of rust. The heat will destroy the bolts into the cat flange beyond simply getting a socket on them and unscrewing them, but getting them out is the worst of what I figure you're facing.

I can usually reach just one of the bolts with a hacksaw. So if you can borrow or invest in a rotary tool with abrasive disks, you can just grind away the other two bolt heads until the cat drops into your hands.

Having already a new cat-back system, you could then remove the bolt remnants from the cat flange with a propane or mapp fueled torch, working somewhere more convenient, on a workbench or concrete. I used a bit of candle wax the last time; they twisted right out so there was no need to drill.

It will take you a lot longer than it would the muffler shop, but you'll know exactly how it was done.
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Art Benstein near Baltimore

You could try to replace the bolts and gasket between the downpipe and cat, but here is my experience: I replaced exhaust system behind the cat, and a few months later the cat went out. I replaced the cat, and a few months later I started getting exhaust leaks in the downpipe. I looked for a used downpipe but found out that at the Pick-n-Pulls that cut out all the catalytic converters (probably a federal or state law). And of course they don't make the cut on the cat side of the flange, they make the cut on the downpipe side of the flange so the downpipes are useless.

I think if it's at the state where the exhaust system is going, it's going. When this happens you're probably best off by just replacing the entire system from the downpipe back.

If you live near Stockbridge I know a guy that may be able to help, he dose work on imports. He has done some work on my 88DL and the service and job was the best. I can give u the number if you like.

Later,
Ace
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88 240DL a.k.a the Blue Tank

Ok your number 3 is practical..You must get the bolts cut flush with the flang,(hacksaw or 4 inch grinder) then you must drill holes in the flang where the original bolts are attached. Make sure you drill a size of hole that you intend to use as a bolt size.. Get two stainless steel bolts and use a lock washer and nut. Use new gasket. It really is not as hard as it sounds just make sure you drill the holes using a punch mark to start the hole. If all fails then do what I just did to my newly purchased 92 244 this afternoon. I used my mig welder and welded the whole thing together.. No leaks and a very solid connection.. Don't catch anything on fire... Of course since you have purchased teh turbo system then I think the bolt replacement would be the better of the two.. Good Luck.:)Max
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Max..1989 244 DL 5 Spd., Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights.