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post #1 of 14 (permalink) Old 02-01-2016, 09:16 AM Thread Starter
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Exhaust Flange Rusted Appart

I have an exhaust leak right now for my 2005 cobalt. I inspected it and it appears the downpipe to catback(not sure if correct term) connection at the two flanges - directly under the center console - is separated. The catback's flange has rusted apart. The area in which it has rusted apart is where the two bolts come through from the other flange.

I am having trouble figuring out how to replace this flange.

1. The bolts coming from the downpipe/midpipe do not appear to be actual bolts. They seem to be more like studs, but have a tapered end to them. I am not sure how when I actually do get the flange replaced, how I can secure these bolts when they do not appear to actually be bolts.

2. How do I repair the flange? I bought a flange replacement from autozone, but it is the wrong size, plus how do I get it over the existing flange and behind it so I can run the new bolts through?


These questions may seem trivial, but I am stumped. Thanks for any help.
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post #2 of 14 (permalink) Old 02-01-2016, 10:04 AM
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Did it look like this?
Have a exhaust shop (somewhere that does custom work) weld in a splice. Or order a new exhaust.
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post #3 of 14 (permalink) Old 02-01-2016, 10:22 AM
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Weld it. If not you can buy a 2 piece flange (you'll want 2) and it will pull them back together. I would personally weld it though.

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post #4 of 14 (permalink) Old 02-01-2016, 11:00 AM Thread Starter
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Yes, that is exactly it. I really do not want to have to pay a shop or order a new exhaust. I am really looking for a cheaper alternative.

Can I get two piece flanges locally? Autozone only had the style I bought, which was the one piece flange, unless I can't figure out how to open it.

How would I go about getting those studs out, or do you guys think I could get rotate the flanges some in order to allow me to put the bolts through without effecting the current studs?


This exhaust is a 2 1/4" right?

---------- Post added at 02:00 PM ---------- Previous post was at 01:50 PM ----------

Was your image of a one broken as well? There obviously isn't supposed to be the gap in between.
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post #5 of 14 (permalink) Old 02-01-2016, 11:18 AM
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I don't know about the downpipe, but I'm fairly certain the stock catback is a 1.75" exhaust. That is, if your Coablt's not an SS.


PJ or MP81 should know for sure.


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post #6 of 14 (permalink) Old 02-01-2016, 11:36 AM
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Buy ours from napa.

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post #7 of 14 (permalink) Old 02-01-2016, 11:47 AM
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Quote:
Originally Posted by pfar54 View Post
Yes, that is exactly it. I really do not want to have to pay a shop or order a new exhaust. I am really looking for a cheaper alternative.

Can I get two piece flanges locally? Autozone only had the style I bought, which was the one piece flange, unless I can't figure out how to open it.

How would I go about getting those studs out, or do you guys think I could get rotate the flanges some in order to allow me to put the bolts through without effecting the current studs?


This exhaust is a 2 1/4" right?

---------- Post added at 02:00 PM ---------- Previous post was at 01:50 PM ----------

Was your image of a one broken as well? There obviously isn't supposed to be the gap in between.
That was my exhaust, i was on a budget with wife on mat leave. It wasn't much money for a shop, i think around 120$ Canadian .... 60$US lol
Or buy a pipe the right size and cut off the flange, add exhaust cement and clamps.

Last edited by beaverG5GT; 02-01-2016 at 11:50 AM.
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post #8 of 14 (permalink) Old 02-01-2016, 12:24 PM
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Think factory is 2" and gmpp bumps it to 2.25" but I've been mistaken before.

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2017 F150 XLT-XTR - 5.0L, 4x4, 3.55's, E-locker, xtr chrome package, fx4 off-road package.
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post #9 of 14 (permalink) Old 02-01-2016, 01:40 PM Thread Starter
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Thanks everyone.
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post #10 of 14 (permalink) Old 02-01-2016, 01:43 PM
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Where I live that's a $40 weld job tops.

2009 Ford Escape Limited - 3.0L, 6 speed auto, 4x4, 25/33 city/hwy imp mpg.
2017 F150 XLT-XTR - 5.0L, 4x4, 3.55's, E-locker, xtr chrome package, fx4 off-road package.
20/25 imp mpg
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