How to repair flex pipe
09-19-2012, 07:06 PM
#12
Senior Member
Join Date: 03-11-2012
Location: Western WI
Posts: 181
They refused to repair free on warranty because their techs could not determine the noises they heard were from the flex pipe. I got confirmation that it was the flex pipe and before I had the private shop do the work I took it back to the dealership with a work order from the private shop telling them on paper it was the flex pipe. They still refused to do the work.
So. Facts and truth are GM WILL NOT, I'll add, in some cases including mine, make this repair under warranty.
09-19-2012, 07:54 PM
#13
Senior Member
Thread Starter
Join Date: 02-19-2010
Location: Buffalo ny
Posts: 1,529
06-07-2013, 08:14 PM
#16
Senior Member
Join Date: 03-22-2012
Location: Rogers City, Michigan
Posts: 1,012
Bowtie
Thank you. I saved this on my computer for when I need it.
Great instructions.
Thank you. I saved this on my computer for when I need it.
Great instructions.
This is my first how to with only a few pictures(via google and my ebay purchase) so please bare with me!
First of all you will need to have welding equipment or know someone that will do some welding work for you. in my case a buddy of mine welds so we did it in his driveway. the bad part is i didn't take any pics which i'm kinda mad about!
1st step is to buy a new flex pipe. i found one on ebay for $37. the one i purchased lined right up on the down pipe and was just a hair bigger than the stock exhaust pipe to make it an easy weld.
[IMG]
[/IMG]
2. if you have a lift it'll be much easier to get it done but i put the front of the car on two jackstands. PULL E-BRAKE!!!!
3. unbolt 3 bolts on down pipe(15mm)
4. unbolt O2 sensor (easy to find, after catalytic converter)i had a special socket for the O2 sensor. it is pretty fragile
5. remove 2 bolts from resonator(i believe)
this is where is ran into a problem. one bolt was too rusted to even move. so we grinded it off and used a new nut and bolt
6. now the section of exhaust should come right out. should be about 3 feet long (just to give you an idea)
7. we cut the old flex portion off. cut it right near the old weld, which was near the blue line on pic below
8. pipe "A" above will fit right inside of new flex fitting
9. slide it together and put back under the car and hand tighten all of the bolt as you will be removing it all again.
10. tack weld the new flex pipe so it will hold exactly where you need it.
11. remove the section of exhaust again
12. completely weld the new section all the way around
13. i sprayed the whole welded area with galvinizing paint(may not be needed)
14. reconnect the section and completely tighten bolts
15. reconnect O2 sensor
16. all finished!!!!!! took us (3 people) about 2 hours
hopefully this will help everybody out!
First of all you will need to have welding equipment or know someone that will do some welding work for you. in my case a buddy of mine welds so we did it in his driveway. the bad part is i didn't take any pics which i'm kinda mad about!
1st step is to buy a new flex pipe. i found one on ebay for $37. the one i purchased lined right up on the down pipe and was just a hair bigger than the stock exhaust pipe to make it an easy weld.
[IMG]
[/IMG]2. if you have a lift it'll be much easier to get it done but i put the front of the car on two jackstands. PULL E-BRAKE!!!!
3. unbolt 3 bolts on down pipe(15mm)
4. unbolt O2 sensor (easy to find, after catalytic converter)i had a special socket for the O2 sensor. it is pretty fragile
5. remove 2 bolts from resonator(i believe)
this is where is ran into a problem. one bolt was too rusted to even move. so we grinded it off and used a new nut and bolt
6. now the section of exhaust should come right out. should be about 3 feet long (just to give you an idea)
7. we cut the old flex portion off. cut it right near the old weld, which was near the blue line on pic below
8. pipe "A" above will fit right inside of new flex fitting
9. slide it together and put back under the car and hand tighten all of the bolt as you will be removing it all again.
10. tack weld the new flex pipe so it will hold exactly where you need it.
11. remove the section of exhaust again
12. completely weld the new section all the way around
13. i sprayed the whole welded area with galvinizing paint(may not be needed)
14. reconnect the section and completely tighten bolts
15. reconnect O2 sensor
16. all finished!!!!!! took us (3 people) about 2 hours
hopefully this will help everybody out!
06-08-2013, 02:50 PM
#17
Technical Moderator
Join Date: 01-23-2009
Location: Fredericksburg, Virginia
Posts: 24,691
I don' remember if it was addressed earlier in the thread, but.... On most HHRs (not all) the upper HO2 sensor bung lives right about were the blue A is in the pic. So you will also need to do some cutting and fitting around the bung.
06-17-2013, 01:58 PM
#18
Premium Member
Join Date: 03-31-2010
Location: Bradenton, Florida
Posts: 154
exhaust flex pipe
Having just had the problem and of course with 84K miles no point in talking to the dealer I researched it here!. Bought the flex pipe part from Rock Auto in Mn. for $45 including postage, called a few muffler shops and found Family Discount Mufflers in Bradenton, FL willing and helpful to do the job for $120.00. Done in 2 1/2 hours and very happy with the work.
Anybody in SW FL needing the job done, I would recommend them.
Anybody in SW FL needing the job done, I would recommend them.
06-17-2013, 03:08 PM
#19
Senior Member
Thread Starter
Join Date: 02-19-2010
Location: Buffalo ny
Posts: 1,529
You are welcome to the people who have thanked me.....I am very surprised at how much these shops are charging...with a lift, this is seriously 1 1/2 hour job. Then again at shop labor hours who knows....anybody near me, I would hook them up for a lot less considering I am a welder now 
