Warped flanges on mufflers

[ecgreen]

I have a warped flange on a muffler and it is giving me fits. The ears on it are bent out and thus the two surfaces are not mating properly and giving me a leak at the bottom of the flange. Solutions? I am think heat and bend it until it fits, but something easier would be nice for once.

[Sloth]

I have a warped flange on a muffler and it is giving me fits. The ears on it are bent out and thus the two surfaces are not mating properly and giving me a leak at the bottom of the flange. Solutions? I am think heat and bend it until it fits, but something easier would be nice for once.

Sawzall?

[Mach2NH]

This the ball flange with the springs? My sister had a similar setup and it was less work to just make a "gasket" out of some soft aluminum to sandwich in between. The soft alum conforms to the imperfections. Going this route has its limitations.

[Sloth]

You might need to get a new joint. It's not cheap either. One of mine had a leak and it needed replace to fix. I tried the new gasket route and it didn't help

[thepinktaco]

I have a warped flange on a muffler and it is giving me fits. The ears on it are bent out and thus the two surfaces are not mating properly and giving me a leak at the bottom of the flange. Solutions? I am think heat and bend it until it fits, but something easier would be nice for once.

Being a 4 cylinder the muffler flange is just a flat 2 bolt. You can buy replacement flanges to weld on if they are really bad. If not I use the copper gasket sealer all the time on rotted flanges and it works good.

[Rubicon]

Sorry I did not chime in earlier, but just remembered that I have used split repair flanges in the past with good result to fix similar issues. Nice thing is that there is no disassembly needed ;)

[ecgreen]

Sorry I did not chime in earlier, but just remembered that I have used split repair flanges in the past with good result to fix similar issues. Nice thing is that there is no disassembly needed ;)

This may actually work. It is the flange between the cat and the muffler on my Bronco II. The ears on the muffler flange are bent away from the muffler, so I can't get a good seal on the bottom of the flange. I am thinking the split repair flanges might apply enough pressure in the right spots to suck up the gap.

[Rubicon]

Sorry I did not chime in earlier, but just remembered that I have used split repair flanges in the past with good result to fix similar issues. Nice thing is that there is no disassembly needed ;)

This may actually work. It is the flange between the cat and the muffler on my Bronco II. The ears on the muffler flange are bent away from the muffler, so I can't get a good seal on the bottom of the flange. I am thinking the split repair flanges might apply enough pressure in the right spots to suck up the gap.