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About normal. Just did 2 of them
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Posted by Noel [Email] (more from Noel) on Sun, 6 Nov 2011 07:23:12 Share Post by Email
In Reply to: Exhaust system - '97 9k CSE turbo - prices and sources?, Todd inMA, Fri, 4 Nov 2011 16:01:28
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Both my 9Ks needed exhausts.

I ponied up the money for the Starla Walker as they fit perfectly and last. My last Starla was almost 5 and except for the flex pipe probably had another six months or so of life. The other had a cheapie the PO had put on and it was junk.

If you can find a custom exhaust shop to bend a pipe to fit you can eliminate the middle muffler. I'd have done that but didn't have the time to get it to a shop and have it done. If you do this, be sure to have the shop weld on hooks for the two hangers. It's important to have some support at that point in the system.

Figure on a couple hours for the whole job. Get new hangers (4). I use a recip saw to cut the pipes, as the bolts are usually seized. The front coupling by the cat can sometimes be a problem. It was OK on the first car, bad on the second one. I cut the bolts with a cut-off wheel on a drill (I don't have air tools). You can also have part of the flange broken. In this case you need a couple of split flange clamps if you want to avoid welding.

I like to hang the center muffler first, then either the rear muffler or the flex pipe. I connect everything but don't tighten all the bolts until the whole system is in place. I also use some exhaust cement on the joints. This makes for a tight seal and no leaks.

Be sure the flex pipe angles UP at the back, otherwise it will hang low and you'll have issues down the road.

BTW, before you order parts check the stay from the engine to the cat. These break and you want to get the part if you need it.

Good luck!

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