2006 Exhaust Repair ?

[oldcodger]

Just found the rear donut gasket leaking but when seeing if the clamp bolts would free off,  the pipe from the front section just dropped off from its flange.

Is there such a thing as a diy repair kit for this kind of thing, as the front section, eg mid silencer and cat, is a one piece item, expesive ?!

If not,  any recommendation of a good supplier of  a complete exhaust ?

[Eddiefh]

Rightly or wrongly I paid £177 at Toyota yesterday out of needing my car back on road , I needed a doughnut gasket and a flat gasket 

[flash22]

so its the flange between the backbox and mid/front section, yes you can get the pipe as repair section

i assume it's a hatch not an estate/saloon, is it a 1SB or JT vin ?

oem - 17410-0D320

euroflo - EXTY3102

 

 

 

[Bernard Foy]

2 hours ago, oldcodger said:

Just found the rear donut gasket leaking but when seeing if the clamp bolts would free off,  the pipe from the front section just dropped off from its flange.

Is there such a thing as a diy repair kit for this kind of thing, as the front section, eg mid silencer and cat, is a one piece item, expesive ?!

If not,  any recommendation of a good supplier of  a complete exhaust ?

Picture would be useful. However, I had a tailpipe drop off years ago. My friend was a welder made a circular metal ring round the outer surface of the pipe welded it to the flange stuck the pipe into the original position and welded it unto the metal ring. I think that the ring was made from a six inch nail. Perfect job no leaks and lasted for years. Hope this idea helps.

[oldcodger]

Hi All,

Thanks for the quick replies, been doing some work on the car just to hold the 2 sections together enough to get it to a garage,   have spoken to a local one and he did talk about welding so he might be able to help 🤞

The point of failure is where the pipe joints the flange as in the pic below.

Seems our system is one continuous run from the engine to that joint by the rear box.

@flash  had not seen that mid section repair kit so that might be a saver, though doubt its a job I will be able to do without a ramp, though if that local exhaust guy cannot weld up the existing part it will be plan B !

Think this place seems to have stock of the part your mention.

https://www.ebay.co.uk/itm/175058811013?hash=item28c2517885%3Ag%3AoVQAAOSw9idaIoNO&fits=Car+Make%3AToyota|Cars+Year%3A2005|Model%3ACorolla

Its a 2006 3ZZE 1.6 Hatch SB1KZ20E30F057624 though not sure I can see what looks like a front box  in that diagram , though we do have two lambra sensors before the 17410 box.

 

 

 

 

[Bernard Foy]

Looking like my suggestion would work, it would be critical to the fix, that pipe and flange are joined at exactly the original angle and original position which might entail temporary stitching and fitting unto the vehicle to ensure a correct fit.

[flash22]

Built - 08/2006

Model - ZZE121R-DHMNKW

part numbers above are correct for your vin

[oldcodger]

Thanks @ flash22,

Having a closer look in daylight the flange around the rear box also looks weak and doubt the rusted bolts will come out of their captive nuts easily, plus with it now off the car there are some other heavy corrosion marks on its body,  so decided to get that mid repair section and a rear box.  Can get the car up a good few inches on 4 of the small car ramps so should not be such a difficult job , hopefully ! 

Just been searching around for those parts, but local motor factors are just not what they used to be and good sites we have used before  eg PartsInMotion  do not list anything like, so seems it may be an eBay order,  though their ratings are good.  

Expect Mr. T will only do a full system at a price more that the cars worth ? 

Still cannot complain as its the first ever exhaust repair in its 16+ years  130k miles life and the first time its off the road.

 

[Crustyoldavensis]

Welding the flange often doesn't last very long. Sometimes it does.

Have a look at aftermarket exhausts, boy racer stuff is often cheaper than OEM.

[Blue Rose]

On 1/12/2023 at 7:08 PM, oldcodger said:

Hi All,

Thanks for the quick replies, been doing some work on the car just to hold the 2 sections together enough to get it to a garage,   have spoken to a local one and he did talk about welding so he might be able to help 🤞

The point of failure is where the pipe joints the flange as in the pic below.

Seems our system is one continuous run from the engine to that joint by the rear box.

@flash  had not seen that mid section repair kit so that might be a saver, though doubt its a job I will be able to do without a ramp, though if that local exhaust guy cannot weld up the existing part it will be plan B !

Think this place seems to have stock of the part your mention.

https://www.ebay.co.uk/itm/175058811013?hash=item28c2517885%3Ag%3AoVQAAOSw9idaIoNO&fits=Car+Make%3AToyota|Cars+Year%3A2005|Model%3ACorolla

Its a 2006 3ZZE 1.6 Hatch SB1KZ20E30F057624 though not sure I can see what looks like a front box  in that diagram , though we do have two lambra sensors before the 17410 box.

 

 

 

 

Mines done the same been told the full part needs replacing :( 

[TonyHSD]

Yeap, it seems like the whole exhaust system contained two parts, front which means everything from exhaust manifold up to rear silencer, perhaps the whole new exhaust will do it. Later Auris , Corolla are pretty much the same. 

[oldcodger]

Thought we would just share our afternoons work as the the new exhaust parts did not arrive today, though perhaps that was asking a bit too much.

Found a piece of steel tubing that nearly fitted inside the existing exhaust tube, the curves of the tubes nicely stopped it sliding in too far

Used some strong kitchen foil to fill it out the tube plus some assembly paste, then with a U clamp ( red arrow in pic)  on the exhaust tube side,  used some chain around the rear flange to draw the two parts together but that was not tight enough so found a two fingered spring clamp fitted between the flange and the U clamp drew the two parts firmly together.

The black chain is just there to hold the spring clamp if it comes off and the silver chain stops the exhaust tube falling too far down if it all comes apart.

Started up and it sounded perfect,  just taken it for a 5 mile spin and all ok, so at least we can get around locally if needed  until the new parts arrive.

 

[DerekHa]

Looks like you managed to use part of a road spring compressor to good effect. A good bit of clever bodging there!

[flash22]

On 1/14/2023 at 12:44 AM, Blue Rose said:

Mines done the same been told the full part needs replacing 😞

Please see above you can get "repair" parts, so you're just replacing the middle box rather than replacing the whole exhaust and cat at great expense

the later auris is a cat back (flange after the cat) so just standard pipe to the back box, so you can slice, dice and splice in a repair

 

[oldcodger]

On 1/14/2023 at 12:44 AM, Blue Rose said:

Mines done the same been told the full part needs replacing 😞

 

On 1/15/2023 at 12:44 PM, flash22 said:

Please see above you can get "repair" parts, so you're just replacing the middle box rather than replacing the whole exhaust and cat at great expense

the later auris is a cat back (flange after the cat) so just standard pipe to the back box, so you can slice, dice and splice in a repair

 

As @Blue Rose car is relatively new could one of these  flexible clamp on fanges be used ?

Various types available from uk stock.

Not really one for us as the boxes corroding as well as the flange.

 

[Blue Rose]

This is what's wrong with mine and that just one of the 100 things that need doing, so not sure if that part would fix. Wish I just did motor machine at college when I was younger would have tried it myself 

[oldcodger]

37 minutes ago, Blue Rose said:

This is what's wrong with mine and that just one of the 100 things that need doing, so not sure if that part would fix. Wish I just did motor machine at college when I was younger would have tried it myself 

 

Thats what happened to ours ,but it was the pipe from the engine, not the rear box, that came away.

Interesting that your flange looks different to ours which has spring loaded bolts,  is yours still the original exhaust ?

Think it all depends on what the condition of the earlier part of the full length  is in ?  they will be very rusty looking, but its down to how solid they really are.

If you can disassemble that flange without breaking the remaining  pipe off, then you could get away with just a new rear box.

If not perhaps you could have one of the above couplers fitted, like this weld on one, if you can find a place to do it for you ?

 

If not,as you can see from this makers web site , if yours is a hatchback like ours, then there is a mid section available or a full system.

http://www.euroflo-uk.com/Catalogue.aspx

We opted for that mid Repair section and rear box.

Note that all the little fittings have to be ordered separately, and would recommend getting these EuroFlo which seems well made, though we were sent a generic rear silencer whih looks poor by comparison.

Have you tried  your local indepenent exhaust shops  for a price ?

 

 

 

[flash22]

The sprung flanges go between the engine and exhaust to allow a bit of flex,

some random link off Google - mild steel flanges https://exhaustpartsuk.com/product-category/exhaust-flange-sets-and-kits/mild-steel-exhaust-flanges-joints/2-bolt-mild-steel-exhaust-flanges/

rose - sorry to say, but that is just rust holding hands

[oldcodger]

@Blue Rose  forgot to say,  that big lump of rust just above the pipe, its the  protector shield for the fuel tank.

Not sure if its even available now,  it was about £180 from Mr. T  but if its too far gone it could be a Mot failure .

Managed to do something with ours a few years ago by pop riveting some extra metal one,  it got us though the mot the last couple of years, you can just make it out in our earlier photo.

[Blue Rose]

15 hours ago, oldcodger said:

 

Thats what happened to ours ,but it was the pipe from the engine, not the rear box, that came away.

Interesting that your flange looks different to ours which has spring loaded bolts,  is yours still the original exhaust ?

Think it all depends on what the condition of the earlier part of the full length  is in ?  they will be very rusty looking, but its down to how solid they really are.

If you can disassemble that flange without breaking the remaining  pipe off, then you could get away with just a new rear box.

If not perhaps you could have one of the above couplers fitted, like this weld on one, if you can find a place to do it for you ?

 

If not,as you can see from this makers web site , if yours is a hatchback like ours, then there is a mid section available or a full system.

http://www.euroflo-uk.com/Catalogue.aspx

We opted for that mid Repair section and rear box.

Note that all the little fittings have to be ordered separately, and would recommend getting these EuroFlo which seems well made, though we were sent a generic rear silencer whih looks poor by comparison.

Have you tried  your local indepenent exhaust shops  for a price ?

 

 

 

Hi yes it's a hatch back and yep went to 3 local and someone who said they deal with only Toyotas (not dealer) they all said the same thing without me saying anything. 

[oldcodger]

3 hours ago, Blue Rose said:

Hi yes it's a hatch back and yep went to 3 local and someone who said they deal with only Toyotas (not dealer) they all said the same thing without me saying anything. 

You left out the key factor  - What price did they quote ?

From looking at various sites it would cost you about £300 to purchase  a full exhaust system, eg about £200 for the front, £70 for the rear box and £30 for the fittings.

You mentioned " a lot of other things " without knowing what they are  - might be time for a  newer car ? 

We thought about the natural follow on ,  an Auris, but all s/hand cars have jumped up in price with Covid and they say the Auris has the biggest increase of all !?