The input pipe connected to my muffler has developed a split running down the side.
With a new muffler assembly costing as much as $286 does it pay to attempt a repair?
I was thinking of cutting out the straight section of pipe and replacing with something from AutoZone?

Thanks,

-Kevin

 

That would depend entirely on how handy you are or what free or cheap resources you have. Also what condition the old pipe you're trying to save and use is in.

If you have a way or know someone who can weld it in for you or you think you can somehow clamp it and you make a good fit then you've saved some money and made a good repair.

The thing to remember is the exhaust pipe you are replacing is not an exact 2", 2&1/4" ... pipe. It's part of the assembly and you might have a challenge getting something big enough to slip fit over it and yet be able to clamp it down. If you're welding it, it's a matter of keeping the proper alignment of the pipes when you start to tack it together and then just filling in the gap as you weld.

I've done a number of repairs where I've taken a can and split it length wise and wrapped it over a pipe and used two or three stainless steel hose clamps to hold it down and they last an amazing time if done properly.

In the end though, you need to replace the pipe with the correct replacement or a good aftermarket pipe or system as the rot will catch up with you in the parts of the system your repair is attached to.