Exhaust weld failed twice...

[carlosdelondres]

Hi, sorry if these questions are old and tired, but couldn't find quite the info I need through the search function.

Just got back from a long trip and was parking up when a weld failed on the silencer (1989 1.6 TD) - the last one on, on just before the tailpipe, where a flat metal plate is welded to the silencer and bolted to the van. The nuts were also loose on the other end of the plate. Initial assumption was that the nuts must have worked loose and allowed the plate to start vibrating, snapping the weld...

Got it welded up, tightened the bolts and went to Dartmouth and back, but same thing happened again when I got home.

I was hoping the repair would last until I could afford a full stainless system from Brickwerks, but may now have to get something I can order off the shelf to get back on the road - but slightly unsure which parts to order (and from where - Just Kampers or GSF or somewhere else?)

I'm assuming that there is something wrong somewhere else for so much vibration as to have broken the part again - my first thought was engine mounts, but the vibration didn't seem excessive before the weld failed. I then saw these:

http://www.justkampers.com/shop/type_25 ... 033251393/" onclick="window.open(this.href);return false;

and was wondering if they, or something similar, ought to be present on my van?

The van was first registered 01/06/1989 so I'm assuming I'll need the following (part numbers are from Just Kampers):

Silencer 1600 TD T25 - J10102 (068251053H) - J10102

Tail Pipe 1.6 TD T25 - J10326 (068251185B) - J10326

Tail Pipe Gasket (Engine - JX) - J13464 (068251235A ) - J13464

2 x Exhaust Mount Rubber (For CS/JX Engine Codes) - J10887 (033251393) - J10887

Silencer & Tail Pipe Fit Kit - J11197 (070298052A) - J11197

Thanks for any advice!

Oh, and one other thing, on the last trip I started noticing an intermittant clonking sound, which seems to be coming from the left rear wheel, speed related but only when in gear - am I right in thinking that it is most likely a worn CV joint?

Cheers,

Charlie

[Oldiebut goodie]

Yes, you should have those rubber exhaust mounts - there should be one each end of the silencer box.
Take a look at Ebay for a system such as this - check it suits your motor.

[carlosdelondres]

Thanks very much!

Looking at the exhaust it seems to be missing one of the mounts entirely, looks as if someone had to cut the bolts off and they were never drilled out...

Ah well, will just have to get it repaired and properly replaced - does anyone know a good VW specialist in the Brighton area?

Cheers

[noss vanagon]

The rubber mounts may solve your problem but the whole set up is not well designed. I have a 1990 1.6TD and the exhaust mounts are a nightmare. When I replaced the exhaust I went through all the mounts replaced missing bolts and tightened everything up, all was well. Then the offside silencer bracket snapped clean in half, this is a 4 or 5mm metal plate so I welded it back up and put it back on, weeks later it broke again. This time I welded it up with an extra plate making it 10mm thick and it has survived. The worst part of the design is the forward bolt on the engine mounting where it joins the sump, the rear 2 are threaded into the sump and easy, but the front one goes through a hole and the nut on the back is a pain to get at so they quite often don't get tightened properly. Good luck with it

[Plasticman]

This is what it should be like, minus the oil and shti,,

and offside

the secret is to have the silencer mounted and secure without any strain on it, you should be able to slide it onto the downpipe and the bolts on the bracket should be lined up.
mike

[carlosdelondres]

Ah brilliant! Thanks very much, just what I need

Can now see that the offside bracket was mounted correctly (until the weld failed at least), but the nearside isn't attached at all, and the bracket on the silencer is too short to reach the mounting point, so it can never have been attached on that side, unless there was something that should bridge the gap which subsequently failed...quite hard to see exactly what's going on on that side anyway at the moment, will have to try to get a better view.

Strange that the nearside bracket wouldn't line up though, unless the box is not the right part in the first place...

Ah well, thanks very much for your help, now hope I can get the bits without too much delay - out of stock at JK at the moment...

Cheers again

[Plasticman]

Got all mine from gsf, box about £50, mountings about £6ish forget the cost of downpipe, the silencer mounting plates hang on I will go take a picky, back in a minute........................................longish minute


bliddy cold out there, right the mounting braket that you see are all there is and they connect straight over the studs on the rubber mountings.
mike

[carlosdelondres]

Brilliant, thanks again!

Now to get the old box off and have a proper look under there

[pirate-pete]

Sounds like your exhaust was in same state as mine was with the missing left hand mounting and the cracked right hand one. Don't think anyone has mentioned yet but you can get a new right hand mount from Brickwerks. I'm not sure if you can get new left hand mounts still but I was able to bodge one by using the back half of the broken right hand mount and drill a couple of holes in it to fit the rubber mount. This has worked well until I find a proper one which has the two rubber mounts fitting to it.

I notice you have a 1989 van and the JK website shows two different exhausts for that year. Their early ones have a sleeve and the later ones a flange at the downpipe to silencer joint. Worth checking which one you need. I wonder if you could put the later flanged setup on an early van if you change downpipe and silencer?

[pirate-pete]

Just found this link if you still need to find new mounts....

http://www.futbus.com/Exhausts/View-all-products.html

[carlosdelondres]

Thanks very much!

Have now worked out that it is the N/S bracket that's missing, ordered from the link very considerately provided by pirate-pete, and all is well again!

Cheers for all the help given,

Charlie

[oldiguana]

got sick of weldin mine back up,so found gsf cheapest for the silencer,but i shelled out the extra and had a new downpipe with the flexi joint in it,which takes a lil' more stress off the mounts,had no meither now in 15 months...used n abused every day!!!!