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Old 09-22-2019, 04:30 PM   #1
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'06 SES 2.0l - Flex Pipe Replacement Confusion

I'm not sure if the previous owner did anything to the exhaust system and I'm a bit confused with what I'm reading online & seeing under the car so want to check with y'all first.

I bought a Walker flex pipe which needs four nuts & bolts, two on each end. Amazon says it's the right part for my car, so I ordered it. I'm a little confused with what I'm seeing under the car. It looks like there's two bolts welded onto the flex pipe at the exhaust header end, and two welded bolts on the resonator (or is it a 2nd cat? not sure) behind it. I've attached a few pics of what I'm seeing.

I'm thinking those bolts are either they're pressed or welded into the metal so it'd be better if I just took it to a shop and had them weld all this stuff together instead of trying to keep the threads clean? Anyone have any experience with this?

First pic is from the rear of the flex pipe, looking towards the engine.
Second pic is a bit further back, still looking towards the engine.
Third is from the front of the flex pipe, looking towards the rear of the car.


Attached Thumbnails
'06 SES 2.0l - Flex Pipe Replacement Confusion-img_20190922_151523.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_20190922_151501.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_20190922_145641.jpg  


Last edited by vjaneczko; 09-22-2019 at 04:37 PM. Reason: added notes for pics
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Old 09-23-2019, 12:29 AM   #2
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Looks like those bolts are pressed in via spines. If your not up to it, easier to have a exhaust shop deal w/ it.
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Old 09-23-2019, 04:36 PM   #3
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I just did a complete exhaust on my 2005 ZX4 5-speed (same engine/exhaust as your 2006) working in my driveway with the front of car on jackstands. It had what I believe to be the original factory exhaust system which was leaking (noisy) badly at the resonator (which I knew) as well as at the flex pipe (which I didnt as the loud sound from the rotted resonator masked the smaller forward leak in the flex pipe). The factory original flex pipe has forward facing pressed in splined studs in its forward flange and the intermediate pipe (resonator) with the integral catcon also has forward facing pressed in splined studs in its forward flange. The nuts that hold the forward flange of the flex pipe to the manicat are fairly inaccessible so I cut the heads off the studs using a air cut off wheel and drove the studs out (forward) with an impact hammer. The nuts holding the flex pipe to the intermediate pipe are accessible but were seized so I cut them off using a dremel cut off wheel without significantly damaging the studs. You dont really need to save the studs there but I did. I replaced the flex pipe to intermediate pipe nuts with new stainless nuts and I used new stainless bolts/nuts between the manicat and the flex pipe forward flange. New intermidiate/resonator pipe does not come with catcon which must be cut and reused. Pics below (sorry if some are rotated 90 or 180). If you have any other specific questions just ask.

Paul
Attached Thumbnails
'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2646.jpg  

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'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2703.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2729.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2744.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2787.jpg  

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Last edited by Paul1958; 09-23-2019 at 08:07 PM. Reason: typo
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Old 09-23-2019, 04:44 PM   #4
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Getting that flex pipe out was a PITA because there is so little working room for the air cut off wheel.
More pics:
Paul
Attached Thumbnails
'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2807.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2815.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2816.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2834.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2837.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2827.jpg  

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'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2832.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2841.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2843.jpg  

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Last edited by Paul1958; 09-23-2019 at 05:11 PM.
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Old 09-23-2019, 04:48 PM   #5
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When I installed the bolts/nuts at the flex pipe front flange I ended up putting the nuts facing rearward. Car is quiet now.
Paul
Attached Thumbnails
'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2870.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2874.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2876.jpg  

'06 SES 2.0l - Flex Pipe Replacement Confusion-img_2889.jpg  

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Last edited by Paul1958; 09-23-2019 at 05:10 PM.
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Old 09-23-2019, 06:30 PM   #6
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Old 09-25-2019, 02:25 PM   #7
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Thanks Paul! That's pretty much what I was thinking would be involved, but unfortunately I don't have the same set of tools as you so I'll have to take it down to a shop. Hopefully they won't gouge me too much...
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