Repair And Fix it

Vehicle exhaust systems consist of multiple parts. In order to properly ship the entire exhaust system, you will need to ship the components separately to avoid damaging them, being sure to keep your packaging to a reasonable size and weight in order to minimize shipping costs. Packing and shipping a car exhaust can be done relatively quickly. As long as it is packaged properly, the parts should reach your recipient in good condition.

Instructions

1

Prepare the exhaust components for packaging. There is a very small market for used car exhausts, so most exhaust systems will be brand new when they are shipped and you should not have to worry about cleaning the parts before shipping them.

2

Wrap each part in several layers of soft towels to protect them during shipping. Exhaust parts such as the muffler and exhaust manifolds are heavy enough that they may not be fully protected by bubble wrap.

Ship each component of the exhaust system separately to avoid the pieces moving and damaging one another during shipping.

3

Locate boxes to ship the exhaust in. Found Value recommends shipping long exhaust parts in five-foot long wardrobe boxes. If any of the parts are unusually heavy, you can purchase specially made double-walled shipping boxes that are twice as strong as regular cardboard boxes.

4

Fill your cardboard boxes with packing peanuts and place each exhaust system part in an individual box. Once you have placed each part into its box, place your packing slip into one of the boxes and then seal the boxes with packing tape.

5

Ship the exhaust using a shipper that regularly deals with large boxes and heavy items. You may want to check with different shippers for possible discounts or promotions. You also may want to select ground shipping for the exhaust system. Ground shipping is less expensive than air, and exhaust parts often cost more to ship because of their size.

Car enthusiasts will often modify a cars exhaust system in order to increase the engine performance or get the noise of the engine to achieve a specific pitch. It requires good knowledge of your cars exhaust system, but it can be completed with a minimum of fuss, provided you follow some basic guidelines.

Instructions

1

Raise the car up on a jack or a hydraulic lift so that you can comfortably work on the exhaust system.

2

Note the part of the exhaust system you wish to modify and the point in the line at which it is found. You may also want to note any part of the system which is fused or rusted, since these will be more difficult to remove.

3

Disconnect each part of the exhaust system, one by one, until you reach the part you want to modify. Generally, a welding torch is required, though you may be able to achieve this simply by removing the bolts that connect it. Take care not to damage any surrounding components in the process.

4

Disconnect the old exhaust part you wish to modify and replace it with the new exhaust part. Bolt it or hang it in place on the chassis, but do not tighten the bolts yet. Check that all of the components work correctly before finalizing the addition.

5

Attach the remainder of the original exhaust system to the new part, working backwards down the line until you reach the end of the exhaust system.

6

Check that each connection is in place and there are no leaks or backups.

7

Secure each connection by tightening the bolts or welding them back into place on the chassis.

8

Start the car engine and check the exhaust system for any leaks or blockage. Make sure exhaust is coming from the end of the tailpipe as it should and that the sound is modified correctly by the muffler, and locate and seal any leaks.

9

Adjust the tailpipe to make sure it is flush with the rear bumper and is not too low to the ground.

Four-wheel drive vehicles receive torque from the engine in all four wheels at the same time. The original concept was to be able to maintain traction to either haul extra weight or drive in tough road conditions, or both. There are two modes of 4-wheel drives. The part-time mode is used for off-road driving or loose road surfaces. The driver is able to switch from 2-wheel drive to 4-wheel drive as needed. Full-time mode is used in all road conditions all of the time.

Differentials

The 4-wheel drive has a differential between the two front wheels and another between the back wheels. During a turn, all wheels are going at different speeds while at the same time, the inside wheels are following a different path than the outside wheels. The differentials allow front, back, left and right wheels to spin at different speeds during a turn by sending the power from the engine to the wheels. The differentials slow the transmissions rotational speed before it hits the wheels. In this manner it behaves as the last gear reduction of the vehicle.

Transfer Case

The transfer case is said to be the component that defines a vehicle as 4-wheel drive. This device splits power between all four axles on the vehicle. The transfer case is used to lock the front and rear axle drive shafts to force the wheels to have the same speed when they are turning. On part-time 4-wheel drive systems, transfer cases have an extra set of gears. These gears give a low range to the vehicle, providing extra torque.

Drive Shaft

Drive shafts enable the transfer case to transmit power from the drive to the front and back axles. The drive shafts are enclosed inside axle housings and transmit the drive to the tires. In part-time 4-wheel drive vehicles the drive is transmitted through the front axle drive only when the driver uses 4-wheel drive.

Locking Hubs

Every vehicles wheels are bolted to a hub. Part-time 4-wheel drive vehicles are equipped with locking hubs that are designed to disconnect front wheels from the front differential when 4-wheel drive is not engaged. The locking hubs also disconnect the front wheels from the drive shaft when a car is in 2-wheel drive.

Electronics

Electronically controlled clutches are used on some 4-wheel drive vehicles. This type of clutch controls torque transfer between the tires in a much more effective manner than older clutch mechanisms. Many 4-wheel drive systems use Anti Lock Brake Systems (ABS). The ABS systems provide brake-traction control when the tires begin to skid.

Automotive exhaust systems muffle exhaust noise and reduce exhaust emissions. While materials and configuration differ among various cars and trucks, all exhaust systems can be broken down into three general sections: the exhaust manifold/headers, the mid-pipe and the muffler/tailpipe.

Exhaust Manifold/Headers

Looking to the front of the engine, the first portion of an exhaust is referred to either as an exhaust manifold or a header. Generally, a header will have individual runners for each exhaust cylinder, whereas an exhaust manifold is one large section, which contains a collector into which all the exhaust gases dump. Many manufacturers now include a catalytic converter into this portion to help reduce cold-start emissions. Note that V8, V10 and V12 engines have two banks and thus a manifold on each side of the engine.

Mid-pipe

The mid-pipe will be the middle portion of an exhaust, starting under and behind the engine, where it meets the exhaust manifold/header. This portion usually contains the mufflers of an exhaust system. In V8 applications, this portion may be an H or X pipe, where the two sides are connected to help equalize gases in a dual exhaust. While a V8 has only a single exhaust, a crossover pipe will run from one side to meet up with the single mid-pipe. Catalytic converters are typically mounted at this point, between the exhaust manifold and the mid-pipe.

When a company refers to a "cat-back" exhaust system, it usually means a system which starts at the mid-pipe, and thus starts behind the catalytic converter.

Some systems may have resonators, devices designed to help muffle the exhaust gas notes, in this portion of the system.

Muffler/Tail-pipe

The tailpipe will meet the mid-pipe near the rear of the vehicle and directs the exhaust gases out to the atmosphere. Some smaller vehicles may have the muffler integrated into the tailpipe section, as the muffler can only go where there is sufficient space.

A trucks exhaust system differs little from that of a car on any other passenger vehicle. Its parameters are dictated by the make and model, though you can upgrade the exhaust system much the way you would an automobile. Usually, it takes a trained mechanic to upgrade any exhaust system, but you can do it yourself if you have the proper skills and knowledge.

Instructions

1

Jack the truck up on a hydraulic lift so that you can work underneath it comfortably.

2

Uncouple the support hangers with a welding torch or bolt cutters, which will allow you to remove the old exhaust system easily.

3

Detach the exhaust pipe, the muffler, the catalytic converter and any connecting pipes one by one, starting with the exhaust pipe and moving backwards through the exhaust system until you reach the Y-pipe intersection.

4

Check the oxygen sensor at the Y-pipe intersection. It may need to be replaced along with the rest of the upgrade, in which case, you should disconnect it.

5

Examine the exhaust manifold, the last part of the trucks exhaust system before the engine. If its part of the planned upgrade, you can disconnect it as well. Otherwise, leave it in place.

6

Install each piece of the new exhaust system, starting with the exhaust manifold and working down the line, piece by piece, until you reach the tail pipe. Each piece needs to be fitted and welded into place, and the connecting pipes fitted and sealed with the welding torch so they do not leak.

7

Check the tailpipe to make sure it exits from under your bumper correctly. You may need to adjust your bumper to ensure that exhaust exits the pipe cleanly. Alternatively, you can attach a turn-down tailpipe, which doesnt need an exit.

8

Double-check all the welds and connections so that each piece is secure. Start the trucks engine and watch for any exhaust leaks, which you should seal with the welder before you proceed.

9

Weld the support hangers back onto the trucks frame and lower the truck to the ground.

Correct tire pressure is very important. If you dont check your air pressure, you could be driving on a low tire, which increases the odds of a blowout. Many accidents are caused by tire failure, and many tires that fail do so because of low air pressure. One fantastic new system available on most new cars is tire pressure monitoring, also known as TPMS. When youve installed a new tire, it is sometimes necessary to reset the system.

Instructions

1

Drive the car at freeway speeds for 50 miles. Many vehicles can be reset just by driving the car. If this does not work, move on to the next steps.

2

Take out your TPMS scanner. Most of the scanners work in the same fashion. Become familiar with how your TPMS scanner works. Notice that the scanner has a menu button and a selector to select your model car. Select your car and follow the prompts on the screen to reset the TPMS units.

3

Reset the tires on the car one by one. This will require you to walk around the car to each tire and push the reset button.

A motorcycles exhaust system is generally easier to upgrade than the exhaust system on other vehicles because the motorcycle is smaller and easier to maneuver around while you work. Even so, it takes good mechanical skills to upgrade a motorcycles exhaust system and you should only do so if youre comfortable with the procedure.

Instructions

1

Remove any parts of the bike that may be blocking the exhaust system. Some models allow you to reach the exhaust system clearly, but others may have crossover pipes from other parts of the motorcycles engine obscuring it. Unscrew them using a wrench and set them aside.

2

Loosen all of the nuts and bolts that connect the exhaust system to the body of the motorcycle, and remove each piece one at a time. Start with the tailpipe and the muffler and work backwards along the system until you reach the head pipes. If any bolts are rusty or stuck, apply WD-40 or give them a few whacks with a hammer.

3

Check the revealed sections of the motorcycles exhaust system for any rust or damage. These sections are normally hidden by the exhaust system, and now is a good time to make sure they are all in good shape.

4

Remove the old exhaust gaskets with a wrench and install new ones for your system upgrade.

5

Spray the new head pipes with anti-seize and fit them into place on the bike. Tighten the retaining collars enough to hold the head pipes in place, but not so tight as to make removing them difficult. If there are any problems with the upgrade, you may need to remove them again quickly.

6

Spray the interior of new muffler with anti-seize and attach it to the pipe. Secure it so that it stays in place, but keep the connecting bolts fairly loose so that you can detach it or adjust it easily.

7

Connect the tailpipe to the assembly of the motorcycles exhaust system, if necessary.

8

Examine all parts of the exhaust system so that they are properly aligned and fit together as they should. Your bolts and fasteners should still be semi-loose, allowing you to make minor tweaks and ensure that every piece fits exactly the way it is supposed to.

9

Tighten the bolts and fasteners on the exhaust system, starting with the head pipes and moving back to the tail pipe. They should now be secured as tightly as possible.

10

Reconnect any of the motorcycles other components that you removed to get at the exhaust system.

Engines produce waste gases which must be expelled in order to maintain power production and fuel efficiency. Exhaust systems route waste gasses outside through piping and system components. Exhaust testing is required by the department of motor vehicles in many states.

Noise Level Testing

State laws vary on acceptable exhaust noise. California certifies state-run testing facilities to determine if a vehicles exhaust meets acceptable noise standards.

Backpressure Testing

Backpressure occurs when exhaust pulls back into the cylinder ports. This suffocates the engine, decreases power and lessens fuel efficiency. Exhaust systems will always have some level of backpressure. Excessive backpressure caused by piping obstructions -- or wrongly sized piping -- requires repair. Testing a vehicles backpressure requires a pressure gauge which reads from zero to 15 PSI. Connect the pressure gauge to the air-pump check-valve and turn on the vehicle. Normal readings are around 1.5 PSI.

Smog & Emission Testing

Smog and emission requirements vary by state. Consult your local department of motor vehicles for state requirements. Smog and emission tests verify a vehicle is not expelling excessive exhaust toxins -- such as carbon monoxide -- into the atmosphere. They verify that exhaust and intake components meet state requirements.

A cars exhaust system removes harmful carcinogens from the engine and helps keep the motor running at peak efficiency. If it is malfunctioning, it affects the cars performance and can even pose a health hazard as harmful toxins are released. Usually only a trained mechanic should repair a cars exhaust system, but if you are sufficiently knowledgeable about cars, you can conduct the repair yourself.

Instructions

1

Raise the car on a jack or hydraulic lift so that you can examine the exhaust system safely, without the threat of the car collapsing on you.

2

Determine the spot on the exhaust system that needs repair. The exhaust system consists of a number of different parts: the exhaust manifold, the oxygen gauge, the catalytic converter, the muffler and the exhaust pipe, as well as different pipes connecting these various parts (usually, only one part of the system is damaged, either through rust and corrosion, bumps on the road or product malfunction). The causes of the damage are myriad, but the solution is invariably either to repair a leaky hole or to replace the malfunctioning part.

3

Patch any leaky holes with a soldering iron, using a metal patch to seal the hole if necessary. This should be done only if the damaged area consists of one leak and the remainder of the cars exhaust system is intact. Otherwise, the entire part will need to be replaced.

4

Remove the exhaust system part by part, starting with the tailpipe and moving backwards to the damaged component. Sometimes, you will be able to remove each part simply by cutting the bolts that hold it to the frame. Usually, however, you will need to use a welding torch to uncouple it and remove any support hangers, in which case take care not to damage any of the cars surrounding components.

5

Replace the faulty component (or components) with a new one, making sure that it matches the parameters of your car and the remainder of your exhaust system.

6

Reconnect the remainder of the exhaust system, starting with the new part and working backwards along the system until you reach the tailpipe.

7

Double-check the fittings and welds for leaks. You can do this with a visual inspection, but you might also want to turn the engine on and run it to see if any exhaust is escaping.

8

Weld the support hangers back on, securing the exhaust system in place.

Loud exhaust systems can result in tickets in many states. They can also be an annoyance to yourself and others. Your exhaust system could be loud either because of alterations intended to increase the vehicles performance, or because of failing equipment. Regardless of the reason, there are permanent as well as temporary ways to quiet an excessively loud exhaust system.

Instructions

Permanent Fix

1

Make sure the catalytic converters and the mufflers are working properly. If they become damaged or have been bored out to increase performance, they can be very loud. In most cases, the check engine light will be on if the muffler or catalytic converter are damaged or altered.

2

Change the mufflers. On most vehicles there are four bolts which hold the muffler onto the tail pipe. If you have dual exhaust, there will be two mufflers. Glass pack mufflers tend to be very loud, but also tend to allow the best airflow. Reactive mufflers are included on most vehicles and are much quieter. Changing your muffler to a quieter one might affect your performance, but can make your vehicle quieter.

3

Replace your tail pipes. Larger diameter tailpipes tend to be louder than smaller diameter tailpipes. Often larger tailpipes are added to increase performance. If you dont want to reduce your tailpipe size, consider a crossover tailpipe. A crossover lets air travel between two exhaust pipes, which causes the pressure to equalize between the two pipes. The result is higher performance and less volume. If no alterations have been made to your tailpipes, this step will not be appropriate.

Temporary Fix

4

Drill two very small holes in your tailpipe, about 10 inches from the end.

5

Shove a wad of steel wool into the tailpipe. The wad of steel wool should go in as far as the holes that were drilled. The steel wool will work as a damper to absorb some of the sound without a dramatic effect on the vehicles performance.

6

Thread the wire into one hole, through the steel wool and out the other hole. Twist it around the tail pipe to secure it.

Your cars exhaust system is designed to carry away gases created when air and fuel are burned in the engine. The exhaust system is vital to your car and can cause problems if not functioning properly.

Function

When fuel is burned in your engine, waste gases are created. These harmful gases exit the engine through an exhaust manifold, which ties into an exhaust pipe to carry them away. Modern cars with fuel injected engines have oxygen sensors to monitor how much fuel is added into the engine for it to function properly. As new fuel is injected and burned, the waste gas that is created is flushed from the car via the exhaust pipe.

Function

The gas created in the engine can cause brain damage or even death if inhaled, so the exhaust system is designed to remove it without exposing you to the fumes. The exhaust pipe is designed so all toxins are flushed out and away from the car.

Warning

It is important to have your exhaust system monitored frequently. Corrosion is a common problem in exhaust systems and holes can allow dangerous fumes to get into your car, harming you and your family. Also, if exhaust gases back up into the combustion area, they can cause damage to your engine.

Occasionally, Ford car fuel systems get air in the fuel line or fuel injection system and need bleeding. Bleeding the fuel line releases this air and allows the fuel system to work more efficiently. Symptoms of air in the fuel line include missing, knocking and stalling. In some cases the car may not start at all. Tools needed to bleed the fuel line allow you to disconnect the line and get rid of any air that may be there.

KD Tools 3321

The KD Tools 3321 Ford Fuel Line Quick Disconnect is available at auto supply stores for around $12 as of 2010. This tool releases the fuel line locking mechanism on new Ford models and fits 5/16- inch and 3/8-inch fuel lines. The quick disconnect tool allows the fuel filter to be released from the fuel line. Once released, the fuel filter can be removed from the fuel line to expose the line for bleeding.

OTC Injection Diagnostic Kits

OTC Fuel Injection Diagnostic Kits allow users to quickly diagnose pressure problems in a fuel line. These kits fit Ford engines that have a multi-port fuel injection system. The kit includes a bleed valve that allows you to bleed air from the fuel line after testing. The gauge assembly lets you check both fuel pressure and fuel volume in the fuel line.

OTC Gauge and Hose Assembly

The OTC Gauge and Hose Assembly tests fuel injection systems and also features a 6-foot bleed hose. The bleed valve on the hose assembly eliminates air from the fuel injection system and also reduces pressure when disconnecting the hoses. The bleed valve can also be used to check for fuel pump volume.

Most stock exhaust systems are single exhaust, meaning that they have one head pipe expelling exhaust from the engine. A dual exhaust system has two sets of head pipes, which allows more exhaust to escape and provides marginally better engine performance, as well as giving the car a more aggressive sound. The difference between them can be surprisingly subtle, however, and if youre in the market for an exhaust system, you should compare the benefits and drawbacks carefully.

Instructions

1

Know the difference between a true dual exhaust system and an exiting dual exhaust system. A true dual exhaust system has two complete sets of the exhaust array-two mufflers, two catalytic converters and two tail pipes-while an exiting dual exhaust system has a single modified muffler with two pipes extending from it. The former provides a genuine boost in horsepower and efficiency, while the latter is essentially a single exhaust system tricked out for aesthetic or stylistic reasons and has no other practical effect.

2

Examine the size of the vehicles engine. You will usually find a dual exhaust system in a V-6 or V-8 engine because they have two exhaust manifolds. Smaller engines tend to have a single exhaust system or else a dual existing system rather than a true dual exhaust system.

3

Compare the difference in horsepower. Dual exhaust systems tend to be better at this than single exhaust systems because there is more exhaust leaving the engine through a second system. This produces more horsepower and improves engine performance, though the emissions they create may not be legal in many areas.

4

Examine the potential for torque, which is usually manifested in the size of the exhaust systems pipes. The narrower the pipe, the more quickly exhaust moves through the system and the more torque the system produces. A dual system tends to use smaller pipes than a single system, which thus produces more torque.

5

Compare the noise levels which the exhaust system produces. Ideally, the difference is negligible, especially if the mufflers are doing their job properly, but a dual exhaust system is naturally inclined to produce more noise than a single exhaust system. The particular pitch and timber of the sound can vary as well, which is part of the appeal of installing a dual exhaust system in the first place.

A cars exhaust system has the job of directing the exhaust gases that are created by the engine safely away from the vehicle. If the exhaust system is not functioning properly, dangerous exhaust fumes could enter the vehicle, putting the occupants at risk. There are several parts that help direct the exhaust gases, extract some of the worst pollutants from the gases, and also reduces the noise of the exhaust system.

Exhaust Manifold

The exhaust manifold is the part of the cars exhaust system that attaches directly to the cars engine block. The exhaust manifold is a pipe or series of pipes that provides a route for exhaust gases to exit the cars cylinders and make their way through the cars exhaust system. The exhaust manifold can be made of aluminum, cast iron or stainless steel.

Catalytic Converter

After the exhaust gases exit the engine via the exhaust manifold, they pass down a pipe and enter a large pod-looking device called the catalytic converter. The catalytic converter is a key part of keeping certain harmful exhaust emissions out of the air. The catalytic converter scrubs certain chemicals out of the cars exhaust with precious metals and chemicals that are packed inside. Catalytic converters operate on heat, so they function at their full capacity once the engine has heated up to normal operating temperatures.

Muffler

Many cars mufflers are visible from behind. The muffler is the large compartment the exhaust tip is attached to. The sole purpose of a muffler is to muffle the noise of the exhaust system. The system of compartments and various materials placed in different kinds of mufflers function to absorb noise so it will not come out the cars tail pipe. If a cars muffler has a hole in it, the car will instantly sound much louder.