Why does my 300e have welded exhaust
 

I have a '92 300e that needs a rear muffler and the exhaust system does not have the usual connector joint on the pipe between the rear and center muffler. I also have a '88 260e which has a joint in the pipe. According to the fastlane catalog, both cars use the same muffler and there should be a clamped connection.

Is it possible that some MBZ models have welded exhaust systems? The center and rear mufflers now on the car are OEM MBZ parts. It looks like I cannot just cut the pipe and attach the new muffler because the joint will fall on a deformed (flattened) section of the pipe. Is there some simple (cheap) way to overcome this problem?

John

The original exhaust system installed at the plant is single piece from the converter back. For service the exhaust system is provided as two pieces. Your '92 has the original exhaust system. The '88 has had part of the exhaust system replaced - probably the center section.

When the center muffler on my '88 190E 2.6 perforated from corrosion, I bought a new center section, cut at the prescribed location and clamped it to the original rear section. The end of the new center section exiting the muffler is expanded to slip over the old or new end section.

Unfortunately if the rear section fails first it cannot be easily installed on the old center section since the original will not have the expanded pipe to slip into. In this case you will need a muffler shop to make the connection or replace both pieces.

The Ansa center piece I bought looked just like the OEM system and fit very well, except it was painted black, and I expect Ansa manufactured the original exhaust system.

Duke

Nothing at all against Ansa, but I am pretty certain the oem was Eberspaecher.

Mine was already 2 piece like your '88.
A local welding shop may be able to adapt the 2 pieces together for you for not a lot of money. I have done similar adaptations on some BMWs, and it is really no big deal. Perhaps design the 'adaptor' section so that it is is welded to the center section, but clamped to the rear section, so that when the center finally goes, you can easily replace it.

'Specialty' exhaust shops tend towards full replacement, and are weld-averse. Their own crap parts are so short-lived, that repairs or partial replace is not usually worthwhile.

Oem quality German exhaust bits are heavy gauge, expensive, and can last 10+ years (as yours did), so repairs/partial replacement can often be justified.

My car was rear-ended a little while ago and I got the entire exhaust replaced with a new Mercedes exhaust system. The entire exhaust is one piece, welded and black. It looks sweet and sounds even better!

Thanks
 

My car probably did have the original exhaust still on it.

I did some careful measuring and if I bought a replacement rear muffler, the joint will be on a round, fairly straight section of pipe. I'm pretty sure I can cut the pipe and fit the rear muffler. If the pipe sizes don't match, I'll get an adaper at Pep Boy's.

Thanks for your help!

My '91 300E came with a one piece exhaust system from the cat back. The OEM replacement is a two piece outfit. I paid $412 for it from Caliber motors. Don't remember if that price included shipping.

They had a heck of a time getting the old muffler off the cat. Had to use an impact chisel to do it.

The original exhaust system was just fine except that the weld to the resonator rusted (from salt) and I failed to have it fixed before it was too late.

where to cut
 

The center muffler on my 87 300e is rusted out. The PO replaced the oem rear muffler with a resonator & welded the unit instead of clamping it on. I'd like to keep the resonator, but how do I know where to cut? Also, can I use a hacksaw or do I need something else? Autozone will do the pipe end expansion for free, which I guess will be needed for the resonator pipe to go over the center muffler pipe. Thanks.