New exhaust system help

[rickprins]

My 2000 OB Ltd MT Wgn has 159,000 miles and is need of a new exhaust system. I need everything including the Cat Conv. How tough is this to do myself? I'm comfortable working on most things on a car (brakes, oil changes, mufflers), but I do not have a lift - I have access to ramps. What can I expect to pay for the parts? What are my any options? I'm more concerned about keeping it quiet than increasing power. Any info/tips is greatly appreciated!

[SHO Type U]

Depending on the car, I'd have a well known shop do my exhaust. Certain cars, u can do without a hassel. But when I had my catalytic replaced, I looked at it first to see if I want to replace it my self. I could have if I really wanted to. But all that crap you can get in your eyes was not worth it for me. If you have the time and the proper tools, you can do it. I'd recommed to have your well known shop to do the work. The stock Catalytic will cost you about $700-$1000, it will probably come from Subaru, in Japan. Labor is about another $100-$200. While your at it, if you have the stock O2 sensors, replace those too, about $100/ each+, you need two of them. So I guess you're lookin at around $1200 all together. Get some quotes, watch out for some shops that will say "well u need this and that" when you're only getting most of the exhaust system replaced and they want to do some other work that don't pertain, u should have an idea what is being replaced and how much it typically cost.

[ivwarrior]

It's possible to DIY. Considering your location, it's likely that most of the bolts are fairly rusty. If I was doing everything from the cat back, I'd make sure I could get the bolts that hold the cat to the manifold out, then I'd use a sawzall and take the rest out in pieces. I wouldn't even bother trying the rest of the bolts. I know when I replaced the cat on my (now gone) Impreza, the cat-to-manifold bolts were rusted and stripped the holes in the manifold out. I used longer bolts, with lock washers and nuts instead.

If you have the tools, and those bolts come out, it won't be too bad. If you don't have the tools (especially to "encourage" rusted bolts) it'll be a pain.

Prebent performance cat-back systems are $$$ and finding a good shop to custom bend one is usually cheaper, but more difficult to find. Many shops do exhaust, some do it poorly, most just get by, and a rare few really do it well. I don't know how an OE style cat back compares price wise to a performance oriented one.

[adler]

the cost is all in what you buy, are you thinking OEM from subaru? aftermarket from a vendor? having a local exhaust shop make one for you?

provided you have good enough room to work, exhausts are easy, and provided you get new bolts. at 159k miles in michigan i'd say dont do it until you get all new hardware so you can just cut/drill the old ones off. they're gonna be wads of rust not bolts anymore. and dont forget new gaskets, nothings worse than doing that job and having to go back underthere cos you thought you could get by with re-using one only to have it leak.

someone to help hold things in place is a great help, especially considering the size of the exhaust system on these cars. i did my honda civics exhaust by myself with no problems, but when i'm under the outback I don't see how it could be fun without someone to lend a hand. easiest way is to buy of a buddy with beer, and maybe a sandwich, always works for me!

do you need to replace your header too? or is that still good? the exhausts studs are a huge pain, the worst of the rusted bits, cos if you break a stud off you have to drill it out, and they go into the engine block. not my idea of fun. you might consider getting an oxygen sensor socket since you're replacing the cat, they make getting those buggers out alot easier.

if you're comfortable doing your own breaks, then you can do this no problem. its no different that putting a muffler on, just more pipe. theres no better way to get to know and understand and even "bond" with your car than working on it yourself.

oh and antisieze all the bolts too, you'll be glad you did should you have to take any part of it off for some reason.

[rickprins]

Thanks for all of the info. I haven't been under it yet to get a look-see. It's been a little cold here in Michigan. Hopefully I'll be able to use the existing header.

Good thoughts on the gaskets... I'll probably would've forgotten to get new ones.