How to Fix a Broken Exhaust Pipe

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There are many reasons why your exhaust pipe will break. Rust leading to holes on a crushed exhaust pipe is one reason. Metal fatigue or an exhaust system that is not in good working order is another. Sooner or later in the lifetime of your vehicle, you will need to fix a broken exhaust pipe. The easiest way, of course, is to take it down to the local muffler shop and let them do it. You save money, though, by repairing the broken exhaust pipe yourself.

Steps

1. 1
   Park the vehicle on level ground, raising it up as high as you can at all four wheels. Put jack stands under the frame at each wheel to accomplish this. The floor of a garage works best.

   
   
2. 2
   Allow the car exhaust system to cool down. Crawl under the vehicle with a drop light to identify the section of exhaust pipe that has been broken.
   • There will be two sections of pipe in most vehicles. The first is between the catalytic converter and muffler, and the second is between the muffler and exit point coming from the under the car.
   • Once you have found the broken section, go to either a local auto supply or repair shop to get the section of pipe you need. Also purchase new exhaust clamps and holders. It is easier to replace them than to try to reuse the old ones.
3. 3
   Lay out the parts and replacement exhaust pipe along with the tools you will need at your work area.
4. 4
   Remove the old exhaust clamps using a set of SAE or metric wrenches.
   • Begin twisting and pulling away the old pipe section to loosen it from the muffler.
   • Remove the exhaust hangers from the pipe.
   • Begin working the pipe out from under the vehicle. You may have to cut it with a reciprocating or hack saw.
5. 5
   Install the new exhaust pipe in reverse order of the removal steps.
   • Weave the new pipe into place under the vehicle, and loosely reattach it to the exhaust hangers.
   • Slide the new exhaust clamps over the end of the new pipe. Now, work the new pipe into place over the old muffler, seating it firmly.
   • Slide the exhaust clamps into place and tighten the nuts. Then go back and tighten down the exhaust hangers.
   • Check your work, making sure all connections are tight. Ensure that the exhaust pipe is firmly secured under the vehicle.
6. 6
   Lower the vehicle to the ground and start the engine. Listen for sounds of exhaust leaks, verifying that the work is complete.

   
   

Tips

• Soak all bolted connections with penetrating oil to make them easier to remove once you start.
• Use a cold chisel and a ball peen hammer on the end of the exhaust pipe that slides over the muffler to encourage it to break free.
• A second set of hands may be needed when weaving the new exhaust pipe under the car.
• Check for places that rent garage space to repair cars and have mechanic's lifts or pits to allow you to get under the car without crawling.

Warnings

• When working under a raised car, always secure it with jack stands for stability.
• Protect yourself from falling debris and sharp metal edges when working on an exhaust system by using safety glasses gloves.

Things You'll Need

• Jack
• Jack stands
• Mechanic's lift (optional)
• SAE or metric wrenches
• Electric reciprocating saw or hack saw
• Penetrating oil
• New exhaust pipe
• Exhaust clamps
• Exhaust hanger
• Ball peen hammer
• Cold chisel
• Safety glasses
• Work gloves

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