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2004 Impreza Subaru Outback Sport (2.5L SOHC)

The rear pipe of my muffler has broken away from from its weld to the muffler body. I would just replace the whole muffler assembly, but the joint where the muffler pipe meets the rear exhaust (#13 in picture) is severely rusted, and I worry about dominoes all the way to the engine if I try to replace it.

Subaru Muffler

Is there a way to re-affix the pipe to the muffler without welding? I'm imagining a pipe adapter that fits around the pipe and steps down a quarter inch or so to fit inside the muffler body. Could then seal it all up with JB Weld or RTV?

Thanks!

tef2128
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1 Answers1

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What you are looking for can be found by googling "exhuast repair kit." It's essentially a sleeve with 2 clamps that you fit over or under (depending on the design) your affected exhaust section. Assuming there is nothing left on the muffler side, you'll only be using the 1 clamp. "Exhaust repair sealant," is the goo you are looking for to seal the whole thing up. This may require cutting a bit of your old exhaust away.

This is not what I would call a high quality repair.

JB weld or RTV are NOT what you are looking for, exhaust gets very hot. It might work for a litle while; JBweld's FAQ suggests it is okay to use far enough away from the cat and manifold. RTV is really only good in thin layers, I worry this would be too large a hole for it to fill. I wouldn't recommend it, but depends how "good" this repair needs to be.

Shop around; There is a good chance you can get it profesionally welded very reasonably, rather than having to shell out again once the repair sleeve fails.

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Zshoulders
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