Club 80-90 Forums

I've fitted a new exhaust to my DG engined van today which eventually was a successful operation. I thought I'd share some useful tips which may help others in the future.

1. Removal of exhaust port nuts:

Actually I had a mixture of nuts and some bolts holding my exhaust in place, but they were all rusted and couldn't be gripped with a normal socked or spanner. I'd soaked them in releasing oil applied over a period of 2 weeks, but nothing would get a grip to the nuts. However I purchased an Irwin Bolt Grip Nut Remover Set and it made the job very easy:





2. All but 2 of the studs could be removed so I replaced them with a set of stainless studs and copper nuts from Brick Parts who are on eBay:

http://www.ebay.co.uk/usr/brickparts-uk ... 7675.l2559" onclick="window.open(this.href);return false;

They were very nice to fit as you could use an allen key on one end of the stud to insert them.

3. I replaced the push rod tube covers with the stainless ones from Brickwerks. Expensive, but they were well made. I did however need to trim one of the covers so it didn't clash with the VW speedshop exhaust I used. I guess the covers are designed to work with the original exhaust.

4. VW Speedshop exhaust went together nicely like many others I read about.

It's a horrible job to get the old exhaust off the van, but as long as you don't beak a stud it's not too bad to fit the new exhaust.

Hope this helps others!

Thanks for sharing.

Yes thanks for this, I'm thinking of doing this...

I have a leaking gasket rear left hand side, I've undone the nuts easily, also the nuts at the union where all the pipes join. However I can't get the pipe to slide far enough off the studs, any help would be good.
Thanks

What sort of exhaust do you have?

It's likely you'll have to dismantle or slide apart that section of exhaust, but if it's a steel exhaust and rusted together it may be challenging.

It's a1.9dg I believe it's a standard exhaust. It's undone and moving I just can't get it back over the studs.

http://www.thesamba.com/vw/forum/viewto ... sc&start=0" onclick="window.open(this.href);return false;

Have a read, some good stuff. Ignore the YouTube video where the guy says ' I hate I hate I hate', he managed to turn the studs a half a turn before they resisted. Very often, they're so badly corroded they resist straight away. Other than that, there's something here for everybody.

It's the flange and tubing I can't get off, not the studs themselves.
My next step is to take the water pipe off the pump see if I get more room

If it's a late 1.9 DG exhaust (85 or later) the rear section will be a single piece for both rear ports which connects to an elbow piece towards the front of the van. Just Kampers website has a diagram of it. You are likely to need to remove all nuts for this section to remove and refit new gaskets.

http://www.justkampers.com/vw-t25-parts ... haust.html" onclick="window.open(this.href);return false;

Removing studs is another option, but that can be troublesome if one snaps.

When I removed my exhaust to replace, I ended up cutting it in the middle once I'd removed the nuts, however I guess you want to reuse your exhaust as its still good.

Proper stud extractor sockets are also good. I've got both sets. I don't mean those worm-like things that snap first go, but ones that grip on to the stud using three rollers inside the socket. Mind you, in some places you can't even get these in. Heat and patience are sometimes the only solution and theres still a chance the stud will snap flush.