jeff968

Hi, my 2006 A4 is sounding like a tank. I got under it and discovered that the center resonator is rotted. The front welds are starting to open up. It looks like an easy piece to replace. I've called a couple of scrapyards and they tell me they don't sell used exhaust pieces. A new one is $900! Rockauto sells something at $130. I saw just the resonator part on eBay for $80 but they cut off the pipes. Has anyone dealt with this? What did you do? Thanks!

Ilya@MainLineAuto

How are you with a wrench and a welder?

mc_hotmail

Yes, $130 is about what I paid for Bosal part# 284-841 from CARiD.com. That part is not the exact OEM part (looks different), but it fits well. Here are some details:

1) Avoid wiggling the flexible mesh-like pipe coming down from the turbo to the clam to the center muffler. That's mesh pipe is expensive.

2) It's very tough to remove the original while preserving the 2 center rubber hangers (good stuff). It is one big Y that includes the 2 rear mufflers. There was no way to rotate the center muffler. I had to cut away a small black plastic piece to have enough room to wiggle the center muffler out of one rubber hanger. You have to spray silicon lubricant on the hangers.

3) That Bosal part is made according to Audi spec, and Audi manual (ElsaWin) for center muffler replacement is to cut the old one away. MEASURE ONCE, TWICE, THREE TIMES BEFORE CUTTING. I cut 2 inches too much, ended up having to add 2 flexible connectors and 4 claims, not expensive, but ugly and regretful.

4) After cutting, you will need to expand/round the original pipes to the 2 rear mufflers for the new Bosal part to INSERT into the old. I didn't have to do that because of that cutting mistake. Expanding and rounding the old sounds challenging.

5) If done right with 3 connectors (like the clam before the center muffler), no welding is needed.

Good luck!

jeff968

Thanks, I purchased the walker replacement and will tackle the job this weekend. I'll let you know how I make out.

jeff968

Well, I just finished the job and it wasn't bad at all.

I used the Walker replacement pipe which looked a little different but installed just fine. It cost only $130 at Rock auto compared to $900 for the dealer part.

Here is how it went:

Jack up the car and place two jack stands. I worked from the driver's side.

Pulling the rubber hangers from the pins was easy. I lubed them up first with WD40 used a larger screw driver to push them to the side off of the pins. Much easier then I thought.

You'll have to cut the pipes, to the rear of the resonator, about 10" back.

You will need two clamp assemblies for the rear.

Remove the front clamp which is part of the system.

With the pins pulled from the rubber, the cuts to the rear, and the clamp from the front, the old assembly well off.

Install was easy:

I first lubed the rubber hangers with grease.

I then lifted the new assembly into place and reattached. With the lube they went on easy and now the unit was being held in place .

Install all the clamps and brackets.

Tighten brackets.

Done.

As for the clamps, you can buy the real nice assemblies from Audi or just get the generic at pep boys.

mc_hotmail

Good for you. I guess you have a FWD A4, which makes removing the old part off the rubber hanger much easier. I have a quattro, and the drive shaft to the rear differential takes up a lot of space.

nicholas muturi

08 Audi A4 Base 8E0253609HE V6 3.2L GAS Resonator Exhaust SILENCER MUFFLER ? USEDPARTSRUS

dgotard

Any feedback on how the Bosal or Walker resonators have held-up? Curious how they might fair through New England winters.

Hayabusafalcon

tard,

STAY AWAY from the BOSAL. It lasted just two Michigan winters then one of the resonators (this configuration uses two ) ditched itself along M-6. It literally dropped off at 75mph and is probably still in the ditch somewhere around Bryon Road. The resonator material is stainless steel yes but the welds are not. The weld seams rusted clean through.
I have found the API resonator holds up better going on four-years now. Sound is virtually same as stock.
here is the info:

Edit added Link: https://www.ebay.com/itm/293158920093


Replaced Bosal center resonator, welds rusted thru.
November 2020
Amazon: Parts Geek
API part no. 18813-07902531 $118

Band clamp, 2.25 in. $10

Band clamp, 2.00 in. x 2 $20

BTW- I have had success painting exhaust parts prior to install with silver (silica-ceramic) header paint. It does delay the onset of rust.

Hayabusafalcon

Follow-up:
Just a thought, and I'm gonna do this next time the resonator fails.....
Just delete the resonator and have your local muffler shop fab a Y pipe to fit in lieu of the resonator (there may already be such available on the web, I don't know, haven't looked.) I hear-tell the exhaust is not loud and is a bit lower in tone but not bad. I just found this...link below. ( Sorry the dude is all about himself-long winded. Scrub to: Before sound at 0:44. After sound: 1:28.)