Hey and Thanks for looking in my thread.

I need some help with this exhaust setup. I am in the market to purchase a new exhaust BUT when I attempt to do that I noticed that mine is different then the ones I see on all the sites. My exhuast is attached by a flange with bolts at the header pipe. Like you can see on the picture. When I attempt to buy one all the ones on the site have some weird type of connection as you can see in the second picture. Please throw a few suggestions around since my car is starting to smell like diesel due to the fact that I have a few holes in my exhaust.

Thank You

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Audi TT

pic one

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Audi TT

pic two

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Audi TT

http://catalog.eautopartscatalog.com/mercedesshop/wizard.jsp?partner=mercedesshop&year=1983&make=MB&model=240-D-002&category=H&part=Exhaust+Seal+Ring

1983 Mercedes Benz 240D
Part: Exhaust Seal Ring
Manifold to Header Pipe
Part # H4002-40405 Exhaust Seal Ring $8.43

Your pipe looks ok in the picture.
The Exhaust Seal Ring, from Manifold to Header Pipe may be bad.

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ASE Master Mechanic
asemastermechanic@juno.com

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
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Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

https://www.boldegoist.com/

more data

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A picture is worth a thousand words, but I'm going to add a few.
There is no incompatibility between the two pictures. The flange is a separate piece that slides over the pipe you show in the drawing and holds the pipe in place.
On my 409d, the vibration of the engine, combined with a broken hanger, had caused the flare at the end of the pipe to break off the rest of the pipe.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

as you can see in my first picture, the bolts are pretty rusty. how would I go about taking those off without breaking them ? would you recommend ordering new ones ? Do I need to order a new flange to slide over the pipe as well ?

you guys are right...i never knew that there was some type of seal there.......

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Audi TT

Soak them in penetrating oil.

Kroil is the best I've found.

After they've soaked, soak them some more. You might be able to break them loose, but I'd be suprised if you do. They look like something I see here in Michigan.

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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

where can I buy a new flange ?

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Audi TT

the flange is a part of the exhaust pipe. If it is broken off you will have to replace the down tube.

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FAA Certified A&P Tech
Still lookin' for my diesel! <><

I will be replacing the whole exhaust from FASTLANE. If you look in the second pic the flange is not on there. whunter said that the flange just slides over the exhaust BUT i cannot find that flange on any website. I have found every exhaust part BUT that.

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Audi TT

Call Fastlane and verify. That flange should included with that downpipe. The fiber o-ring is seperate.

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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

the funny thing is that I called FAST LANE and whoever I spoke to had no idea what I was talking about. He said that he didn't have a picture on his computer

That is why i'm hopefully trying to figure it out here on these forums.....

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Audi TT

Call "Performance Prducts" 1-800-243-1220
or www.************************


David

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1985 300D Turbo

The flange is not included with the down pipe.
The fiber o-ring and down pipe are available from WorldPac.
The flange is transferred from pipe to pipe and is a rare item to replace, unless it is lost.
The bolts that hold the flange to the manifold must be replaced, but they are standard sizes.

Note:
The flange should last 60 years, even in Michigan road salt.

Note #2:
I just reviewed Performance Products online data for your car; they do not offer the flange either.