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Discussion Starter #1
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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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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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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Discussion Starter #4
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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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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Buy ours from napa.
 

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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.
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.
 

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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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Where I live that's a $40 weld job tops.
 

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My brother paid 15 bucks to have something very similar welded up on one of his old cars. Check around and you might be suprised how little it could cost to get it welded up
 

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Just had this problem last week.. Good to know it's a common problem. I tried to do it myself but with no welder it was kind of a pain, ended up paying $100 to have it done at a local shop. Almost miss the noise it made lol.


Sent from AutoGuide.com Free App
 

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It's a super common problem on almost all vehicles.
 
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