'92 300d 2.5 turbo

Driving today, just coasting in 4th about 1/8 of a mile from a red light, no traffic around. Light turns green and I pedal down. Downshifts to third about 55mph and I'm winding it out. Revving up about 4000 just before it would up shift to 4th..... WHOOOOSH!!!!

All of a sudden the exhaust sound is abnormally loud and I can hear the turbo spinning. Other wise driving fine. Maybe a tad more power actually.

Wasn't far from home so I continued on. Get home and pop the hood to take a look and I can see right away...

The flexible section of exhaust pipe right behind the turbo is torn open right at the top.

WTF?? Either it physically got ripped by engine twist while under high load or it somehow blew out because of excessive back pressure.

Any ideas?

__________________
Current fleet
2006 E320 CDI
1992 300D - 5speed manual swapped

former members
1984 300D "Blues Mobile"

1978 300CD "El Toro"

Perhaps some of each. We ran flex pipes on the dynos that were made of that same SS convoluted tubing and from time to time they'd fail due to flexing and heat cycling. Ours were used pretty much all day long, 5 to 6 days a week so it was kind of an extreme duty cycle.

FYI, this stuff is a BUGGER to weld, especially if it's coated with, say, Diesel soot. So I'd plan on replacing it. A good welding shop might be able to change out the flex section and clean up and reuse your existing flanges but it might be cheaper to order up a new one already assembled. I haven't looked at price or availability but someone ought to offer these.

A quick look on Pelican does not turn up that piece.

Either way, you'll need to repair/replace that one. When you do that I'd be sure to check downstream for any issues as there might be a plug in the system somewhere. Or poke a hole in the right front fender and....... Oops, maybe not practical for everyone.

Dan

Haha. It actually doesn't sound terrible. I'll be damned if it doesn't feel a bit stronger as well.

Can anybody come through with a part number the get a replacement for that small section of flex?

__________________
Current fleet
2006 E320 CDI
1992 300D - 5speed manual swapped

former members
1984 300D "Blues Mobile"

1978 300CD "El Toro"

Universal flex pipe with smooth bushings on each end can be gotten from Walker , Maremont, AP and other exhaust vendors.

The ones on my two OM617s have a very tight tolerance V-band flange and accompanying clamp to hold them together. The fit is tight enough that they're a stinker to assemble and you have to hold your mouth just right and stand on your left foot while hopping slightly to get it to fit together. Seriously, it's SO tight that I thought I had the wrong piece but someone on here told be that it's just that hard to assemble it and sure enough once I got it just right it did fit.

All this to say, I think it has to be the correct piece. I'd be amazed if a universal hunk will do the job. 97SL320 - I wonder if you're thinking of the flex pipe down stream a bit. From Philly's description I'm thinking it's the one right at the turbo. Or maybe I have it wrong.......

Dan

They are vulnerable. You might also find a broken hanger on down the line which put undue stress on the down pipe.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

I'll get a picture tomorrow in the daylight

__________________
Current fleet
2006 E320 CDI
1992 300D - 5speed manual swapped

former members
1984 300D "Blues Mobile"

1978 300CD "El Toro"

You mean the accordion section in this picture of a 190D 2.5t, not the braided flex section in the near vertical portion of the downpipe, right?



Sixto
83 300SD

That's a bit different from my OM617s but the same concept. The turbo gets hot and grows bigger so there has to be an accommodation for that. My previous comments still apply.

Dan

just want to follow up. Thanks for the replies.

what tore open was actually an approximately 10'' section of flexible pipe in the front section of the exhaust system. when i went to take it apart the reason why it broke what obvious. One of the mounts on the hanger that is attached to the transmission had let go letting the exhaust pipe hang down about three inches an put extra stress on that flexible section.

went to McAuto parts store and grabbed a generic flexible section. cut out the old section and welded the new piece in.

__________________
Current fleet
2006 E320 CDI
1992 300D - 5speed manual swapped

former members
1984 300D "Blues Mobile"

1978 300CD "El Toro"

OK, I was thinking the other piece of flex. You did EXACTLY the right fix! Looks good and pretty nice welds.

Dan