How to Replace an Exhaust Flange for a Smooth and Efficient Ride

Before you start, make sure your car is cool and off the ground by using jack stands. To replace your flange, you’ll need two flanges of the appropriate size, two nuts and bolts, a hacksaw, a drill and bits, protective eye-wear, WD-40, a ratchet set, and a small vise grip.

Start by cutting the top of the curve off one flange with the hacksaw and the bottom of the curve off the other, so that when you put them together, you have one complete flange that fits over the pipe. Place the two flanges one on top of the other and use the drill with the proper size bit to drill one hole above the opening on the right, then drill through both flanges below the hole on the left to fit the bolts.

Once the new flange is prepped, you can remove the old one from the manifold. To do this, spray the bolts with WD-40 or bolt remover and try to unbolt them. If the bolts won’t budge, you may need to cut the flange off, being careful not to saw into the pipe going into the muffler or catalytic converter. Once the old flange is removed, use a rag and WD-40 to remove any remaining rust from the manifold.

Now that the worn-out flange is removed, slide one-half of the new flange over the top of the pipe, then the other half over the bottom of the flange, making sure the holes line up correctly. Insert the bolts, nut side up, and use the ratchet to securely tighten the bolts. Finally, give the bolts one last check to make sure everything is snug before you finish the job.

Replacing the flange in an exhaust system is an easy fix that’s much better than replacing the entire exhaust system. Just make sure you have all the necessary tools and follow these instructions, and you’ll find yourself with a like-new exhaust system in no time.