Exhaust System Replacement

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gsnod

Joined
Dec 24, 2004
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Location
Massachusetts
Hi All --

My 2003 Mitsubishi Outlander is making enough noise that I sense it's in need of a new exhaust system. I'm toying around with doing it myself. I'd put it up on ramps and jack stands, and just do it.

Any suggestions, advice, or ideas where I can get a complete exhaust system? Perhaps NAPA or Advance?

I'm also going to call around and try to get some estimates from Monroe or Midas, etc.

Appreciate any insight!
 
VIP discount auto is good for exhaust parts, they're all over ME and NH and have a couple on the north shore of MA too.

Advance has mufflers; check their website out, may have to order mid pipes etc.

If it's just a muffler, and you're the first guy to futz with it, a lot of the time you just sawzall the old one off, the new one will slip over the midpipe and you pot a clamp on. Done.
 
Originally Posted By: gsnod
Hi All --

My 2003 Mitsubishi Outlander is making enough noise that I sense it's in need of a new exhaust system. I'm toying around with doing it myself. I'd put it up on ramps and jack stands, and just do it.

Any suggestions, advice, or ideas where I can get a complete exhaust system? Perhaps NAPA or Advance?

I'm also going to call around and try to get some estimates from Monroe or Midas, etc.

Appreciate any insight!


Get it done at a shop. Get a Stainless Steel pipe put on and it should last the life of the truck. Not sure why the current one hasn't... Being a 2003 ?!?
 
+1 on the stainless. IF that is what it is, then it should last longer than six years. On my oldest car with a stainless system (10 years) is still very sound metal. And that is here in one of the WORST salt areas (last year they used so much they ran out of salt!)

If it is not stainless and is truly rusted out or otherwise in need of replacement I would have to put in a vote for an OEM system. My daughter's car (a Honda) needed a new pipe between the converter and the muffler. I bought a Bosal pipe (reported to be the "same" as an OEM) and it was nowhere near the quality of the original. The OEM was a far heavier gauge of metal and was double-walled. I returned the Bosal pipe and purchased the Honda pipe from an online dealer. It was twice as expensive ($200 vs. $100) but well worth the money. Just my $0.02, I have found in the past that OEM exhaust fits better and is of superior quality.
 
If you decide to do this yourself, find a mom and pop place and have them remove and replace any fasteners to which you will bolt the new system.

I.E. when I purchased a new Borla catback system, I had the shop replace the fasteners from the cat to where the new system attaches. When I drove home, I was $20 lighter in the wallet, but dropping the existing system and bolting up the new one was a snap.

Best $20 I ever spent.
 
Thanks for the comments and recommendations. I'm going to put it up on the ramps this weekend when I do an OC to see where (and if) I've got soft spots.

I believe I've got a weak front exhaust pipe, which comes right off the exhaust manifold. It does sound like I might have a leak in that area. This car only has 50K miles on it, has the OEM exhaust system. My subaru lasted 12 years and was still OK...

I'll let everyone know what I find out on this Saturday or Sunday.

Thanks for the thoughts!
 
Stuff a rag in the tailpipe and idle the truck. If it shoots the rag out, you don't have a leak. Otherwise, it'll help you find it.

Could be a heat sheild resonating or saggy exhaust mount maybe. Front pipes, before the last cat, are usually very robust metal... except at flex pipes. You might have one or those spring loaded joints with stuffing (generally reliable)
 
Eljefino's method may not work very well if it is a small leak. I'd spray 50 / 50 soap water along the entire system and watch for bubbles.
 
Thanks very much all for the great ideas. Luckily, we're supposed to have reasonable weather this weekend for me to get under and try to lock down the location.

I'll let ya all know what I find out this Saturday or Sunday.
 
Just out of curiosity do you do a lot of short-distance driving? If I'm not mistaken, most exhausts rot out from the inside out due to acidic moisture build up in the piping caused by a lot of short-distance driving.
 
Last edited:
OK -- time for an up-date on what I saw today. First of all, the system from the catalytic converter to the back is solid, so the bulk of the system is not an issue.

Where the noise is coming from seems to be the front exhaust pipe, right after the flex tube. This section (after the flex tube) is covered by a heat shield (which is loose -- but not the source of the noise).

Does anyone know whether is is all one piece (from the exhaust manifold to the catalytic converter)?

The next question is whether I can actually get the piece off to replace it...you know the issue -- rusted bolts and tight working area.

Thoughts?
 
Sorry to reconnect after a month long hiatus; I took the car to the dealer, and low and behold, the front exhaust pipe was replaced under warrenty. Evidently, Mitsubishi extended the warrently to 8 years on that section of pipe, since they had corrosion in that area.

So, thanks all for your advice!
 
Glad it worked out!
thumbsup2.gif
 
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