I would like to know the pipe diameter (and thus clamp sizes) for the exhaust pipe after the flex pipes and before the center resonator; also for the pipes after the center resonator and before the LH/RH mufflers.

The center resonator needs replacement, so I am ordering Bosal Part Number: 7440-05100838 from Partsgeek.com

partsgeek.com lists 50mm clamps forward and 42mm clamps after, however I have been to Shop A and Shop B and they both just simply quoted 2 inch clamps.

Shop A quoted over $2400 for the repair, they are not even living on the same rock as the rest of us. Note they insisted on replacing everything from flex pipe aft.

Shop B quoted $962. $70 of labor, they told me (and I agree) that the rear LH and RH mufflers are in great shape, and just the center res needs replacement. $676 for that part, and $38 a piece for clamps (4). They are willing to use customer provided parts, but their labor with be $125-$150 instead.

So to order the correct clamps, I was wondering if anyone knows for a certainty what the factory pipe sizes are. 2 inch? or 50mm and 42mm.

For reference I was thinking about:
7440-05100838 Muffler (1x) $216
W0133-1634113 50mm clamp (2x) @ $12.85 each
W0133-1919708 42mm clamp (2x) @ $14.85 each

from partsgeek.com

if they are just 2 inch, can I get away with the 2 inch band clamp 7440-05119134 ? $2.85 each or must I use the dual clip type as listed above?

Thanks, this stands to save me a bit of cash and help keep our A6 on the road.

P.S. Yes I know 50mm is about 2 inch.

 

This doens't answer your question, but how come the resonator is so pricey? Are you going with OEM replacement?

If so, do you care? Why not put an aftermarket, non-OEM replacement, since your car isn't new? Shouldn't be $620 for the part itself.

 

These systems last forever. When ours finally cracked through at 250k, I just bought a used one for $50.

 

It's pricey because shops like to inflate parts prices to boost profits. In this case, a muffler that i can find for $215 is being marked up to $700-$900.(this why their labor rate changes for their sourced parts vs customer sourced parts.

When you say used i take it you mean go torch one off an A6 in a junkyard? Since the factory original is stainless steel, this is an intriguing idea. But you never know how bad of shape it will be in and how long it will last. The Bosal one i'm looking at new should at least last 4 or 5 years.

 

I have a similar issue on a 2001 A6 Quattro and it looks like the same system. Mine was originally a MN car so the hangers for the resonator had rusted off and the whole system was sagging. I removed the old rusty hangers and used a piece of rebar to make a bracket to hold up the resonator using the original doughnuts.

Why not take your car to an independant shop and have them bend a couple of pipes to replace the resonator? It would probably cost a hundred bucks or so out the door. It is a 13 year old car and there is no reason to spend more than the car is worth on a resonator.

Have a nice day
Steve

 

A number of people who did away with the resonator came back because it makes the car too loud even for normal driving. Especially true on 4.2.

At prices of less than $300 for aftermarket resonator, shouldn't be a problem. At $600+, I would go to a different shop.

 

The problem isn't sourcing an resonator/pipe. I can order that for $216. I'm trying to figure out the clamp sizes. I believe they are 50mm and 42mm (2 fore and 2 after the resonator) but I'm not sure on the size. I was posting in order to avoid jacking the car up on 4 jackstands and sliding under with a creeper to measure the pipes. (Not fun compared to standing up under a lift).

I have found a shop that will install customer brought-in parts, so I don't want to pay $645 for a resonator and $38 per clamp (4 clamps!) when I have found the same parts for much less.

The more I think about it, if I'm going to creep under the car, I might as well cut out the exhaust with a torch and just clamp the new one in myself and save the $150 in labor. Anyone done DIY exhaust before?

Thoughts?