Opinions on Exhaust for 240D?

[PackerEdgerton]

Hi guys,

I was picking up my kids from school, and went over a speed bump at the school. Suddenly, I heard a 'clunk', and the sound of the exhaust from underneath the car became REALLY loud! Yep, looks like the pipe connecting from the resonator to the rear muffler just snapped in half! WOW! I had no idea the little om616 produced so much SOUND! WhooHoo!

So, I went to the local independent muffler shop.

Here are the options:

1) Full stainless system from down pipe to tailpipe, including new resonator and new muffler: $750

2) Full aluminized system from down pipe to tailpipe, including new resonator and new muffler: $590

3) Splice into the down pipe (reusing the connection to the manifold) and replace MOST of the connecting pipes, reusing the existing resonator and muffler (they look in decent shape): $250

Right now, I am opting for #3. Do you guys have guidance or opinions? I am happy with the existing sound and performance.

Thanks,

Packman

[Stretch]

Well loud pipes save lives!

I wouldn't bother with options 1 or 2.

Of the options listed I'd go for #3 but I'd investigate the cost of a complete system from other sources (such as fastlane etc) to get an idea of what the material costs.

[t walgamuth]

It sounds like you could just replace the down pipe..

[ftwchopper]

Also It sounds like $250 is a lot for just splicing in a small length of pipe.

[gatorblue92]

All of those seem high to me. IIRC I think I paid around $300 for a complete cat back flowmaster setup for my old Ford Ranger. This was about 10 years ago though.

[Simpler=Better]

New/patched pipe work back to the stock resonator/muffler is the quietest. You shouldn't have to pay more than $250 though. Be sure that they understand your car doesn't have a catalytic converter in it, and the front "turtle" is a resonator.

Personally, I'd go with a glasspack style resonator slipped inside a hood stack:

[PackerEdgerton]

Originally Posted by gatorblue92

All of those seem high to me. IIRC I think I paid around $300 for a complete cat back flowmaster setup for my old Ford Ranger. This was about 10 years ago though.

Yes, I agree they all seem rather high.

I am currently 100 miles away from home, and stopped by a custom exhaust shop. They got great ratings on Google. Everyone else (Midas, Meineke, other shops) got really mixed reviews.

I patched the break with some epoxy and muffler wrap. It's barely holding together.

The owner put the car on the rack, and allowed me to see everything under the car.

Overall, it's apparent that someone has been splicing in pieces of pipe to fix leaks over time. The splices have been been simply "cut and clamp" kinds of repairs. I could see this before the guy said a thing.

I'm pretty sure much of the system is probably pretty old or original. Surprisingly, the resonator and muffler are in decent shape. Rest of the system really looks pretty rusty and in need of replacement.

Basically, the guy is going to save the resonator and muffler (reuse) and then replace everything else except for a small section of down pipe that connects to the manifold.

I can call him to change my mind in the next hour or so.

Thanks,

Packman

[whunter]

Originally Posted by PackerEdgerton

Hi guys,

I was picking up my kids from school, and went over a speed bump at the school. Suddenly, I heard a 'clunk', and the sound of the exhaust from underneath the car became REALLY loud! Yep, looks like the pipe connecting from the resonator to the rear muffler just snapped in half! WOW! I had no idea the little om616 produced so much SOUND! WhooHoo!

So, I went to the local independent muffler shop.

Here are the options:

1) Full stainless system from down pipe to tailpipe, including new resonator and new muffler: $750

2) Full aluminized system from down pipe to tailpipe, including new resonator and new muffler: $590

3) Splice into the down pipe (reusing the connection to the manifold) and replace MOST of the connecting pipes, reusing the existing resonator and muffler (they look in decent shape): $250

Right now, I am opting for #3. Do you guys have guidance or opinions? I am happy with the existing sound and performance.

Thanks,

Packman

Where are you ?

IMO the prices are EXTREME high end.

The exhaust on my 240D was replaced last summer from manifold to bumper.
A local independent exhaust shop bent/flared all of the pipe, and installed a basic muffler at the rear.
It took about an hour.
Total parts, labor tax cost $275.00 USD.

Look at these prices for a full OE system from Mercedes.

Down pipe
MB# 123-490-35-19
Pelican Parts - Automotive Parts and Accessories - Porsche & BMW

Central RESONATOR
MB# 123-490-46-15
Pelican Parts - Automotive Parts and Accessories - Porsche & BMW

Muffler
MB# 123-490-45-15
Pelican Parts - Automotive Parts and Accessories - Porsche & BMW


CURRENT PRICE for a full OE system from Mercedes.
$40.00
$345.75
$263.00
I come up with a total of $648.75


.

[vstech]

yeah... I'd run from that shop.

all muffler shops are going to have mixed reviews. ignore that and go look at them. you should have no problem getting that tiny pipe replaced for under 100 (heck, for 20.00 at any auto parts place, you can buy a splice and clamps...)

[PackerEdgerton]

Thank you kindly guys for all the thoughtful replies. I ended up staying with the shop and I must say, they do great work. Beautifully-radiused bends (rats, I forgot to take photos!), nice even welds, very careful copy of the factory exhaust system. The tech put it back up on the rack for me to view his work. (Nice!)

They did indeed cut into the factory down pipe and then replaced EVERYTHING aft of the cut point except for the factory resonator and muffler, which are in surprisingly good shape (I suspect they've been replaced before - they still have the three-pointed-star and "123-" code clearly stamped on them.) The tech mentioned that he was surprised at what great shape the factory resonator and muffler were in ("Good choice keeping them - they are in terrific shape. I'd do the same thing") He simply bent 2" pipe to exactly match the factory system, including welding in "bump points" where the factory put in bumpers in case the exhaust is pushed upwards towards the car. There are a minimal number of weld-joints, and he cut the resonator and muffler out and simply welded the pipes to that. Nice job flaring, bending, and welding. This guy obviously takes pride in his work, and it shows. I was duly impressed.

The 240D is back to it's (relatively) quiet personality. Power and sound is as before... possibly a bit quieter. I'm very happy. I think it should go the distance.

Thanks again guys,

Packman

[vstech]

2" pipe? should be 1.7 I think...

[t walgamuth]

Originally Posted by vstech

2" pipe? should be 1.7 I think...

Shouldn't hurt anything.

[PackerEdgerton]

Originally Posted by vstech

2" pipe? should be 1.7 I think...

Yes, they mentioned that they had no metric-sized pipes, and that they used a SAE size that was slightly larger than the metric exhaust diameter that MB uses, hence a change from 1.7" to 2.0".

Sincerely,

Packman

[SD300]

OT if my 300sd to remove the 2 butterfly resonators would it increase power?
any louder than before?
as i still have the orig muffler in the end.

i was told a small hole developed on those Y section, which i am not going to replace them.
TIA

[charmalu]

Originally Posted by SD300

OT if my 300sd to remove the 2 butterfly resonators would it increase power?
any louder than before?
as i still have the orig muffler in the end.

i was told a small hole developed on those Y section, which i am not going to replace them.
TIA

Here are some links/pic on center SD muffler replaced with a straight pipe.

Replacing Muffler/exhaust line... '85 300D

300SD Muffler Removal

Surgery on 300SD Resonators that were pulled

Center Resonator/Silencer


Charlie