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Discussion Starter #1
Afternoon all.

My 2004 Outback 2.5 has been sporting a slightly different exhaust note of late.

I took a look under it this morning with the engine running, applied low revs and saw puffs of exhaust coming out around the join as indicated below:


Sub_Ex by Mark and Kirsty Beaman, on Flickr

More worrying ( I think) were the drops of water coming out as well. (Not oil or petrol as it didn't smell of anything.)

Grateful for the the thoughts of the forum on what the problem is and whether a job for a local garage or main dealer to rectify.

Thanks in advance.
 

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Yes, that is the answer, a new "doughnut" gasket. You may have to fix the flange on the converter side in case it's not going to hold up.
 

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Also, water condensation, especially on cold startup, is normal. Burning of fuel when fully efficient is meant to produce two things: CO2 and H2O (water). It's the reason you see fog when you fire up a car in the cold, its the reason cars driven short distances and never allowed to fully warm up rust out their exhaust systems. When the car is warm enough, the condensation is evaporated off and that produced remains a vapor until it is well beyond your tailpipe.
 

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Stuff rags into the exhaust pipe end(s) to see if that is your only leak. Mine was leaking badly at the Y connection leading to the rear L & R mufflers. Walker Exhaust Systems called that pipe the Resonator Pipe, as it does have a small resonator on it. When the car was idling, the windows in my house were rattling from the low-pitched noise it made!

With about 120K miles, the exhaust system should have lasted longer than that. My other vehicle's exhaust system must be stainless as there is not a spot of rust on the entire system!
 

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I put a metal cutting abrasive blade in my circular saw and just cut the bolts right off and installed new bolts and springs with the donut.
 

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Discussion Starter #9
Okay, I've had a couple of quotes by independent repairers one of which said that I needed a new centre and rear, £1700 fitted!

The other more independent and less money grabbing said that I needed a new centre section only. There is a hole in the pipe on the left had side of the picture above, so it isn't just the gasket that is leaking.

He could only source orignal Subaru bits so it would cost just over £1000 + £40 labour. His advice was to try and get an exhaust kit from somewhere on line which he would be happy to fit or even have an exhaust specialist make a centre section which would probably be a cheaper option.

So, my next question - where to look for an exhaust kit or a specialist who can make the centre section for me.

Thanks, as ever, in advance.
 

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Are you convinced that new parts have to be installed, beyond what is required to repair the flexible joint?
 

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Discussion Starter #11
No, I'm taking the garages word for it.

However, I am inclined to believe the second garage as they are willing to to fit the bits that I source for them and they are only going to charge me £40 for the labour. If they weren't prepared to do the work unless they were providing the parts and therefore making some profit on the bits I'd be less inclined to believe them.

My hunting on the 'net has identified this part:

Subaru Legacy 2.5 Litre Centre Pipe with Silencer 2004 onwards - Legacy - Subaru - Hayward and Scott

Thoughts?
 
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Beamers74
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