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2008 Ltd 4.6L needs muffler side flange from where Y pipe joins.

Discussion in 'Stock 2006 -2010 Explorers' started by pjw73nh, July 8, 2017.


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    1. pjw73nh

      pjw73nh Active Member

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      2008 Ltd 4.6L 120k. I am in need of a replacement flange for the muffler side of where the Y pipe comes down and joins the first muffler. Just under the drivers door.

      The flange and pipe on the Y pipe are solid and good. The bolts and muffler side flange are rusty, The muffler flare is still in good condition, It is just the bolts and spinning two-hole flange that are corroded.

      I have looked all over. Walker, Fx Exhaust, AP etc. None of them have anything bigger that 2.5".
      If you look at this picture https://www.dropbox.com/s/5z0yvnkllbumrgq/Flange Markedup.jpg?dl=0 you'll see my measurements. Yes 2.70" OD for the pipes (not on the flare) and 5.2" OC for the bolt holes.

      I could probably get by with just the gasket (ordering it on Monday) and a new bolt/spring set. But I don't think there is much life left in the spinning muffler flange.

      This 2.7"/2.75" OD pipe seems to be a rarity as far as flanges go.

      The rest of the exhaust system is in good condition and does not need replacement.

      Anyone else run into this issue?

      Thanks.
       
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    3. Explorer_PL

      Explorer_PL Elite Explorer

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    4. pjw73nh

      pjw73nh Active Member

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      Yes, saw them all. Nothing available bigger than 2.5" . Thanks.
       
    5. pjw73nh

      pjw73nh Active Member

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      UPDATE: I ended up ordering the donut gasket from the local dealer. $22. I measured the ID of it DEFINITELY 2.75 ID I installed it yesterday. Due to limited access/workspace in the vehicle, it took me about 1.5 hours to get each of the rusted bolts off. I used a dremel to cut a slice in each of the nuts and then one hit with a hammer and a cold chisel and the nut splits off. It took all of 10 minutes to put the gasket and bolt/spring kit in. It sill leaks slightly, under pressure but way better than it was. The Y pipe and flare pipe from the muffler don't seem to mate perfectly, there is a slight angle to the joint. I think when I had manifolds done years ago, they may not have got them aligned perfectly. It's good enough for now.

      Thanks for the info
       

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