Honda Pilot - Honda Pilot Forums banner
1 - 13 of 13 Posts

·
Banned
Joined
·
379 Posts
Discussion Starter · #1 ·
Hey people! I have a 2004 with an exhaust leak in front on that flexy looking piece of pipe that has the mesh wrap, know what I'm talking about? The mesh is off and there are holes in it. Exhaust smell is really bad inside vehicle. I've fixed many exhaust leaks either by "Mickey mouse" or welding or whatever. I have never had to fix this part before. Right now replacing it isn't an option. Has anyone patched or taped this thing up with any success? If so what did you use? TIA.

Rich
 

·
Banned
Joined
·
379 Posts
Discussion Starter · #3 ·
No. It's not a flat surface. It's flex so it's an "accordion" looking pipe. It will have to be wrapped. I'm just wondering what others may have used. I guess I'll just buy some exhaust repair crap and give it a go! LoL
 

·
Registered
Joined
·
11,809 Posts
Obviously your entire exhaust system needs to be inspected by a professional and repaired properly. If your going to keep driving it without a proper repair job, there is some stuff called Exhaust Wrap. This is not a long term solution. This may improve your situation and save you a few brain cells. Carbon Monoxide inside your car can kill. I recommend that you don't use the vehicle until it's fixed properly.
 

·
Banned
Joined
·
379 Posts
Discussion Starter · #5 ·
Obviously your entire exhaust system needs to be inspected by a professional and repaired properly. If your going to keep driving it without a proper repair job, there is some stuff called Exhaust Wrap. This is not a long term solution. This may improve your situation and save you a few brain cells. Carbon Monoxide inside your car can kill. I recommend that you don't use the vehicle until it's fixed properly.

I know this. I have replaced whole exhaust systems so I'm not new to this, but I have never repaired this type of pipe. I'm just looking for a quick fix until I can cut and weld. I was hoping someone had some luck and could recommend a certain product.
 

·
Registered
Joined
·
1,653 Posts
That is called a flex section. You can get a new stainless section welded in, but it cannot be soldered or wrapped.
 
  • Like
Reactions: Nail Grease

·
Registered
Joined
·
3,631 Posts
I have a 2004 with an exhaust leak in front on that flexy looking piece of pipe that has the mesh wrap, know what I'm talking about? The mesh is off and there are holes in it. Exhaust smell is really bad inside vehicle. I've fixed many exhaust leaks either by "Mickey mouse" or welding or whatever. I have never had to fix this part before. Right now replacing it isn't an option. Has anyone patched or taped this thing up with any success? If so what did you use?
The best way to repair this flex pipe problem is to replace it with a new front pipe. Front pipe is available from Walker but OEM is somewhat more expense. The biggest obstacle is loosening the bolts which are rusty and likely to crumble or snap. Temporarily I have covered the broken mesh part of the flex with some metal flashing and clamps.
One thing I don't recommend is visiting a nation-wide chain muffler shop who will cut off the old flex and unsuccessfully weld in a new one. In the attached picture I used an inspection mirror to look down upon this half-assed weld job that was subsequently covered with exhaust putty that blew off.
 

Attachments

·
Banned
Joined
·
379 Posts
Discussion Starter · #8 ·
The best way to repair this flex pipe problem is to replace it with a new front pipe. Front pipe is available from Walker but OEM is somewhat more expense. The biggest obstacle is loosening the bolts which are rusty and likely to crumble or snap. Temporarily I have covered the broken mesh part of the flex with some metal flashing and clamps.
One thing I don't recommend is visiting a nation-wide chain muffler shop who will cut off the old flex and unsuccessfully weld in a new one. In the attached picture I used an inspection mirror to look down upon this half-assed weld job that was subsequently covered with exhaust putty that blew off.
Thanks. I realize it needs to be replaced. The new pipe is on order. As I said, I was looking for something temporary to just keep the smell down. I wrapped it in metal tape and that did a good job. I plan on replacing the whole pipe. It's an easy job and I'm not too worried about it. The nuts on the flange at the cat are the only ones in tough shape, but I'll just cut those. Thanks
 

·
Registered
Joined
·
11,809 Posts
The best way to repair this flex pipe problem is to replace it with a new front pipe. Front pipe is available from Walker but OEM is somewhat more expense. The biggest obstacle is loosening the bolts which are rusty and likely to crumble or snap. Temporarily I have covered the broken mesh part of the flex with some metal flashing and clamps.
One thing I don't recommend is visiting a nation-wide chain muffler shop who will cut off the old flex and unsuccessfully weld in a new one. In the attached picture I used an inspection mirror to look down upon this half-assed weld job that was subsequently covered with exhaust putty that blew off.
Your not supposed to look that close! Lol but ya, going back with new is always better. These shops want to get you in and out quick. There are some videos on YouTube that can help in getting those rusty deteriated bolts out. Heat up with a torch then a rapid cool down with water and hit with an impact looks like a good method. If your not in a hurry and you don't have a torch, I've had success with brake fluid as a penetrating lubricant, but sometimes the bolts are just to far gone.
 
  • Like
Reactions: TJS and aggrex

·
Registered
Joined
·
1,653 Posts
I was told that Walker now uses aluminized steel flanges on their SS Y-pipes. Magnaflow uses full-SS.
 

·
Registered
Joined
·
2 Posts
I know this. I have replaced whole exhaust systems so I'm not new to this, but I have never repaired this type of pipe. I'm just looking for a quick fix until I can cut and weld. I was hoping someone had some luck and could recommend a certain product.
So Honda has discontinued the Y pipe with flex for 2004 Pilots. Only after market now. The parts guys at honda dealer said welcome to the world of honda LOL. I tried Bosal but did not fit. Flanges to the exhaust were wrong shape. Could grind down but the stud holes did not even lineup. ugh Trying Walker now. Waiting for parts. Looked at putting just a new flex in as that is what was starting to leak but that was a no go. Of course getting the up stream o2 sensor out was also a no go so went with a new denso. Genuine at dealer was 245. Paid 60 for denso at local parts store even cheaper on line. Unlocking the snap connection for the o2 sensor in engine bay is total PITA. Come on Honda. Had to grind off the nuts at the pipe to Cat flange then drove bolts out with a hammer. Will probably have to drive the new ones that have a spline feature back in with a hammer. Oh by the way have to remove underside skid plate brace for access. 4 bolts. Impact used. Suprisingly. the easiest removal were the pipe to exhaust manifold nuts. Impact again. The nuts holding the rubber bracket for the Y pipe were way rusted and took some time to slowliy get out as there is a captured nut above you absolutley do not want to strip. Hint, I have been burned by ordering exhaust stuff on line that doesnt fit and returning is way difficult so I use good local autoparts store(no national chains). I pay more but no question asked returns if they dont fit. I will keep you all posted on the Walker install. I quess if that doesn't fit on to ANSA. I would rather go to the dentist than do rusty exhaust work.
 

·
Registered
Joined
·
3,631 Posts
So Honda has discontinued the Y pipe with flex for 2004 Pilots. Only after market now. The parts guys at honda dealer said welcome to the world of honda LOL. I tried Bosal but did not fit. Flanges to the exhaust were wrong shape
The exhaust repair adventure on my 2004 Pilot started with flex section replacement @meineke which could have worked if the repair was done correctly. Old rusty exhaust work is difficult as I had the same issues that you experienced. I had to cut the bolts off my OEM CAT as the bolts+nuts had morphed into one solid rusty mass. Went with a Bosal exhaust system and the fit was good. Bosal or Walker are probably not as good as OEM but the aftermarket exhaust systems are more affordable and the OEM is no longer available. It was very easy to DIY install a new complete aftermarket system rather than try to adapt the new front pipe to the old exhaust system. I used SS fasteners to simplify replacement the next time. Shopped at RA for the NGK O2 sensors
 

·
Registered
Joined
·
2 Posts
Glad your job went well. The bosal didnt fit for me but the walker did with a little crow bar action. Walker was $100 less than the bosal too. Did modify the upper connection location for the o2 sensor incase have to replace again. At 110,000 miles and 16 years old probably wont have to do this job again. On to the small oil leak at the oil filter housing gasket and another small oil leak coming from either valve cover gasket at the EGR or the gasket for the EGR. And front lower control arm bushings showing some cracking. Always something. Keep calm and carry on.
 
1 - 13 of 13 Posts
Top