Trying to get my son's S40 ready for inspection and it sounds like the exhaust is leaking from the flex pipe. Any recommendations for a replacement?

I could just have the old flex joint cut out and weld in an new but the other pipes look pretty rusty. This car only has 60K miles and wasn't driven enough to dry out condensation in the pipes.

I see some complete down-pipes with converters on ebay for cheap. Anyone have experience with these?

Thanks
Stan

 

wish we could buy used cats out here in Cali - but big brother won't let us

 

If not in California, you can either buy a new catalytic converter which includes the flex pipe for about $325 (49 state version). I did it that way since I wanted to get a guaranteed fit and avoid welds etc and used the opportunity to freshen up the O2 sensor as well. Bosal does market just the flex pipe section for about $20 - but you'd need to pull the cat to cut/weld in the new section so expect do also replace the O2 sensor. FCPEURO.COM sells both (located in CT so fast shipping on the east coast).

 

FCP Euro is my friend lately.

Did you get the pipe with the cat from them? Did you DIY or have a shop do it?

 

I got the whole cat from FCP. Install is not that hard. there are three bolts into the manifold/turbo (studs can rust up so plan on patience and penetrating oil) and then the coupling to the center exhaust. If you have a shop do it, expect about 1.25 hours give or take for the job. Expect the O2 sensor to get stuck too :-) so I'd buy a replacement if you go DIY