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Old 01-29-2015
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Join Date: Jan 2015
Location: East Haven, CT
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My exhaust flange repair, 97 Ranger


Thought I'd share my exhaust flange repair I did last night. I have a splash-model 97 Ranger 2.3 and the flange between the cat and downpipe was rotted away. I'm a mechanical newbie and don't really do much automotive repair...

Clearly the gasket is worn away and the bolts are rusted badly.

This is what I bought, all from Napa:

Split-flange repair kit:

Donut gasket:

Spring bolt kit:

Now... not for nothing, Napa parts are kinda crap. I don't know what's up with that. It's like going to True Value hardware to get a good set of tools... I'm digressing but I am basing this on an experience I had with front rotors on my VW that warped within months, and this stuff I just bought. The parts are super expensive for what they are. I think I paid 28.00 for the flange kit and it came with a huge burr on the inside of one of the mounting holes and no nuts. I found some that worked and had to drill out the burr. Just more work for something that should be all set at that price. I'll learn from it I'm sure...

I ended up cutting the old flange off and then zipping the bolts off at the nut using a standard Dremel with metal cutting wheels.

To put it all together wasn't that hard but required a lot of modifications considering I planned this pretty well. I had to open the holes in the cat-side flange to fit the new spring bolts in, and my one and only drill bit snapped on the other side leaving me no choice but to use a different bolt for now so I could just get out from under there and get it done.

In the end, I'm satisfied with the repair and it did the job, and quieted the obnoxious leak.

Now i just hope it lasts a couple years!
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Old 01-29-2015
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Good job
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