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Exhaust snapped after flexi

Discussion in 'A4/S4 forum(B5 Chassis)' started by voteforpedro, Feb 8, 2010.

  1. voteforpedro
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    voteforpedro Member

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    So today my exhaust sheered clean in half right after the flexi joint... Fortunately my new exhaust is in limbo between my house and the Parcelforce depot and comes with this section.

    I guess it bolts up to the cat, and those three bolts will be a PITA to remove. Wanted to avoid having to replace it if possible, but looks like God intervened. :)
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  2. voteforpedro
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    voteforpedro Member

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    P.S. I need to get my car home... It's only a short distance but don't want to blow the turbo... Is this possible with no exhaust?
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  3. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator

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    you wont blow the turbo, best exhaust for a turbocharged engine is as big and as short as possible.
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  4. voteforpedro
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    voteforpedro Member

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    Sweet, may leave it off then! Sounds awesome. ;D
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  5. voteforpedro
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    voteforpedro Member

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    Bah. So I ordered a stainless steel sleeve to join the two exhaust sections and it was too small. I ordered 60mm (will fit up to 63mm apparently) and there's no way it will fit over the pipe. What's the most common size? It's a Powerflow btw.

    Also, where can I go to buy one off the shelf in Birmingham? Do Halfrauds sell them?
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  6. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator

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    the biggest one audi do is 60mm afaik.

    You'll need to measure the outer dia of your two pipes.
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  7. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    The sleeve is powerflow, or the Exhaust is?
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  8. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    Not that it matters, get yourself onto ebay and buy a clamp on flexi, just choose your DIA and as long as the pipes are clean and the old flexi cut off out of the way. Should be a simple slot in and clamp on, around £20 iirc for 65mm ish
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  9. voteforpedro
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    voteforpedro Member

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    Thanks for the advice but the exhaust was fooked in several places. I bought a Powerflow exhaust off eBay for the bargain price of £40 delivered. The sections were welded together, including the downpipe which is welded to the centre section. Looks I have no option but to remove the downpipe. :(

    Anyway, today was full of lose. I removed the old exhaust but didn't get very far with the 3x 13mm bolts on the cat. They are a PITA to get to! Any tips? Won't be able to have a go till next weekend now so looks like another week without an exhaust. :(
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  10. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator

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    with mine, i unbolted the cat from the turbo, pushed it down as far as it would go, then jammed the grinder thru it from underneath, and then pulled the remains out the top.

    the bolts were just 3 blobs of rust!
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  11. voteforpedro
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    voteforpedro Member

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    If I unbolt the cat from the turbo, I can just drop the cat/downpipe together. Good plan except they'll be hard to separate off the car, without a vice anyway.
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  12. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator

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    hacksaw (or grinder) thru the bolt heads ;)
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  13. voteforpedro
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    voteforpedro Member

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    Is there enough clearance to drop the cat through the cavity?

    That could be misinterpreted. :)
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  14. voteforpedro
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    voteforpedro Member

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    Another thing I noticed: the three 13mm bolts on the underside of the cat appear to be bolt heads, not nuts. I thought the bolts were welded to the cat and the heads should be on the top, nuts on the bottom...
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  15. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator

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    nope its just normal nut and bolts.

    I couldnt fit the cat down thru the cavity, and i couldnt fit the downpipe up thru the cavity, hence getting the grinder out.

    Apparently if you remove the driveshaft heatshield though, it gives you more room and it works, though YMMV
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  16. voteforpedro
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    voteforpedro Member

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    Grrr... The bolts are mounted upside down on the cat>dp, i.e. the bolt heads are on the bottom and the nuts are on the top. I don't think you can easily get to all three nuts from the engine bay? Also, they probably aren't welded on which means they'll spin unless I grip the bolt head and nut at the same time (impossible).

    Looks like I'm going to have to remove that cat.
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