Flex pipe and Cats

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Jul 23, 2011 | 08:34 AM

old96A4

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From: sunny , snowy central New York State

Flex pipe and Cats

Took the A4 to the muffler shop this morning, they said they couild fix the flex pipes again. Nothing to cut and weld to any more after the first time welding in new flex pipes. So they wanted to charge me $1800 to replace both cats from the mainifold. they said it's not a bad job. Any one done this before?? I'm thinking of buying the BOSAL cats for $265 and replacing them myself. any comments?? link to doing this job??
I want the car to last one more year if I can..

Jul 25, 2011 | 04:45 PM

eCoastAudi

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Flex Pipes

Find a more ambitious muffler shop. At the worst, you could remove the down pipes to get better access and easier welding. If it's not too bad wrap the things in muffler tape / exhaust epoxy. For $1800, you could probably find another '96!

Jul 25, 2011 | 05:16 PM

4Driver4

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Quote:

Originally Posted by eCoastAudi

Find a more ambitious muffler shop.

Agreed.

Jul 25, 2011 | 05:17 PM

old96A4

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From: sunny , snowy central New York State

If I could get the flex pipes off I'd replace them. I'm look for infor on how to take the flex pipes off the mamifold. Looks pretty tight in there to me. And also if any one used the BOSAL converter pipe, I read some place some one used one on a 1997 A4 and the pipe didn't fit correctly.
Didn;t fit the flange correctly, but not sure what happened.

Jul 25, 2011 | 05:50 PM

4Driver4

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You need to cut the old flex joints out with a sawzall, track weld the new joints in place, drop the cat pipe down to finish the welding, then reinstall. It's not rocket science, but more of an art.

Your chances of success decrease rapidly if you plan to remove the pipe first. Leaving everything in the car ensures that the finished product will line up.

Find a good shop.

Jul 26, 2011 | 03:07 AM

old96A4

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From: sunny , snowy central New York State

THe problem is the flex pipes have already been welded once and there's no room to cut on teh cat side. They would have to cut into the cat to get it to work. I didn;t think it was that big of deal but they woudln't do it. but you're right I'll find a second opinion some place. I would think you could cut the flex pipe off put in another one and at least put some universal cats on and a new pipe. yjey didn;t want to mess with it again. there were the same guys that did it a few years ago for me for $100 a side. they just did my A6 for the same price. SO these guy aren't all bad. I just don;t know where they get their pipes from. I was just floored on the price they gave me. came down to $1500 real quick when I told them to take it down.