Rusted Flex Pipe on a '15 Grand Caravan Saved $700 on Exhaust Repair

I got an estimate for $1000! I saved $700 by doing it myself. These are the tools I bought for the project and the parts. Hope this helps you save $$ too :)
Tools
- Ingersoll Rand 114GQC Air Hammer
amzn.to/42qTwxV
- Impact Chisel (the OEM Tools set I bought has vanished from shelves but this is the one you need. I found it at Napa for a good price): www.napaonline...
- OEMTOOLS Pipe Expander
www.autozone.c...
- Sawzall - I already have one, but they are available everywhere at different price points. It is one of my most used power tools.
Parts
- Walker Exhaust Pipe 54902
amzn.to/44qoKqB
- Two 2 1/2" exhaust clamps
amzn.to/423dzTc
Contact Me
Web: clickthruvt.com
email: [e-mail]
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[@OneJennifer247]

My caravan has 262,000 miles runs like a champ. Im preparing for this job next.

[@sstressfl]

Awesome mileage! Wow!! We're running ours as long as possible! At 150k still smooth as can be and great gas mileage. Im thankful you can find plenty of parts availability and good prices compared to many other vehicles. Have fun! Be safe 🙏🙏🙏

[@mikeyb4real]

Great video and walk through. I'm nearly finished with this job. Note to others: if you plan on doing motor mounts, do them while you have this section of tail pipe off. It makes the rear motor mount a LOT easier.

[@sstressfl]

Good tip! 👍

[@PjBug]

It’s the best feeling in the world when car parts and tools work exactly as intended! Wonderful work

[@sstressfl]

I completely agree!! To think through a problem, devise a plan (with help sometimes!), assemble the tools and parts, put it into motion, then see it come to completion and actually work!!! It’s so rewarding 🙏😎💪😁

[@DF-zp1os]

AP exhaust (rock auto)makes the down pipe with mandrel bends, not crunchy bends on walker. I just finished replacing my walker replacement pipe that lasted 4 years in northern mn weather. Welds to the resonator rusted out.

[@sstressfl]

Good to know! I planned to get a couple years out of it living in VT 👍 4 years is better than I expected!

[@garyphloyngam7148]

Thanks for this information rockauto it is 👍🏾

[@alanfrancis6946]

Have the same issue with my 12’ Chevy Sonic. Exhaust is completely off now because of that flex pipe. Only 1ft of pipe coming off the turbo. It is certainly loud and could be dangerous as you mentioned. Just out of curiosity I used a gas detector for going into confined spaces…2 seconds after starting it was going crazy with the CO level going through the roof…still alarmed after windows rolled down. Nothing to let slide for to long.☠️ Nice repair!👍🏻

[@sstressfl]

Wow the fumes are really dangerous! With the right tools, and a little shopping for the parts you can get it done :) Looks like you need to remove the 02 sensor too. That can be tough if its rusted. Might need to buy a new one for the new pipe. Prices arent too bad though for the parts.

[@mostlymoparih5682]

Good job. Amazing how much difference there is between say Walker and OEM exhaust parts. FYI I don't get the pep pep pep noises anymore when i do exhaust work. I put Permatex tailpipe sealer on the pipe ends before I install them. It gives a little lube to make the pipes slide together and also seals the little holes so no little noises that you have to tighten the clamps more for. My 2012 TC pipes still look good but I'm a couple states south of you. So by doing the job yourself ya saved seven bills and got some free tools. Happy Motoring.

[@sstressfl]

I had some of the tailpipe sealer that I used to install my motorcycle exhaust! It works great! Perfect tip for this kind of install.

[@curtisboutelle6334]

The grommet tool makes removal extremely easy

[@sstressfl]

I see that! It’s perfect for removing the exhaust hangar! Better than a pickle fork! Lol but hey the pickle fork made it easy too 👍

[@mdb831]

A brave man does this job on his back.

[@sstressfl]

Gettin it done 😃

[@yarikoptic]

Greetings from a Norwich'ian neighbor! I am just bracing to do this job, thanks for the walk through.

[@sstressfl]

Greetings 👋 I’m so glad it was helpful. Thanks for the feedback my friend 🙏❤️

[@jeffersonbiongcog1648]

Whoohooo! I had the same expression when I first cut that pipe behind the resonator. Great video, btw!

[@sstressfl]

Love it!!! Thank you for the feedback🙏😎💪👍

[@mairybee]

woohoo! thanks for the vid. I found a smaller kit on ebay for $70, doesnt include the coverter. Seems to work but I really had a tough time shaping the new grommet rods. Really loved you in Wedding Crashers!

[@sstressfl]

😂 thank you. The roles haven’t come since then so I’ve found creative expression in YouTubing 😁 Glad you got it figured out. And I imagine shaping the hangars was not easy. Thanks for the feedback and encouragement 🙏

[@realetnancy]

Thanks for the advice ❤

[@realetnancy]

My husband just changed his, but I’m still dizzy when I take the van. The only thing I can see is that he didn’t make sure the pipe was exactly round. The other thing, he used an original second hand. This means that the metal is thicker. Maybe he didn’t tighten the metal band enough 🫤

[@sstressfl]

It might be a good idea to put it back up in the air, make sure its safely supported on proper jack stands with a hydraulic jack in place as well, start it and you can feel around the pipe to see if its puffing exhaust out of the clamped areas. If it is, then it needs to be tightened :)

[@DIYBuilds]

great video. thanks for your efforts

[@sstressfl]

Thank you 🙏

[@gregbragdon6946]

Thanks for the video. Just went through this exact repair.

[@sstressfl]

Awesome 👍 thanks for the kind words 🙏

[@JMonty215]

Need one on 2018 dodge caravan gt but im afraid 😂 same symptoms but not as bad 🤦

[@sstressfl]

You can do it 💪😎 Has been perfect since the fix 😃

[@JMonty215]

@sstressfl This looks stressful, is there no other way to install the flex pipe ?

[@sstressfl]

@JMonty215 you could pay somebody? You do need some good tools. Sawzall is a must. Or a grinder with a cutoff wheel i guess would work but hot sparks always make me nervous. And that air chisel with proper tools makes it possible.

[@supersawyer358]

I have a 2012 town and country with the same problem. Looks like the same exact part. And I'll definitely need the help of Jesus, brother .

[@sstressfl]

God is good 🙏🙌 Prayers for your success brother 🙏

[@supersawyer358]

Update......I literally could not get the flex portion off with my air chisel. Come to find out the air chisel was the problem had a Lowes kobalt and that was useless. I used the one from my work, which is 3 times the size, little drove it off in 15 seconds. After that everything went together really smooth. What brand is that air chisel you use ?

[@sstressfl]

I did read about chisels and there are weak ones that just don’t hit hard enough. The best are commercial grade like you used for work. I’m glad it came off and you got it done 🙏🙏🙏

[@rick5644]

First off Mike.. Cool man cave! Second, I'm sad to hear you'll be selling the ole girl in a couple years.. She has given you the OK to abuse her and then it's dump time? Lol. At break time or any kind of celebration you're suppose to crack a cold one. All in all, awesome job on saving some dough on this project! You deserve a gold star sticker to add to your Hall of Fame board :)

[@sstressfl]

We’d keep her forever but the salt simply eats cars in Vermont. She has definitely worked hard but it’s inevitable 🥲 and I did crack a cold one!! A Diet Coke 🤣 thanks for the kind words Rick 🙏💪😎 Till next time!

[@Kate_Zander]

Hey which tool did you use out of the oem chisel set? I see it’s a popular item and is sold out. 5:16.

[@sstressfl]

This is the tool I used! kzbin.info/www/bejne/bmOcn398oKZsmbssi=_lPraMCz-Ii_fvHd&t=613

[@sstressfl]

This is just like the one I used Air Hammer Chisel Outside Muffler Cutter www.napaonline.com/en/p/NPT65320

[@shawnisaacs1159]

Got the air hammer and am attempting this. What size of air compressor did you use? The box says it requires 20 cfm, but that would be a tank. Any thoughts?

[@sstressfl]

If you got the same one I used it specs say Average Air Consumption: 4 CFM at 90psi. I am using a cheap Home Depot compressor that delivers 4 cfm at 90psi.

[@mattdaniels249]

Mike - great video. What do you know about the resonator (immediately downstream of the flex pipe) going bad? My T&C rattles / resonates at 1200 rpm under load but not when parked and rev'ing up the motor. I'm wondering if the innards of the resonator have rusted loose. Thoughts?

[@PeterMetzger]

My 2012 caravan does the same - awful buzzing/resonating sound from 1200-1500 RPM but only when under load.

[@PeterMetzger]

further update: on mine it was that the vertical face on the back side of the resonator had rusted free - once air can escape around the edges it will get louder and louder until it fails. I'm now ordering all the replacement parts to replace this, though my flex pipe still looks great, so I'm considering trying to just replace the resonator (cutting it off from the larger assembly) rather than the whole thing. @sstressfl do you have any thoughts on if that would be a feasible operation?

[@sstressfl]

I don’t know how I missed this!! Yes the resonator has baffles inside. Can rust and fall apart and rattle. You should be able to determine that is the cause by using an auto stethoscope or a broomstick (touch one end to the pipe the other end gently to your ear).

[@sstressfl]

Totally feasible but consider that it is very common for the flex pipe to fail due to rust. I’d hate to see you replace the resonator then have to replace the flex pipe soon afterward and buy the part all over again :/

[@79W200]

​@PeterMetzger does yours do it at like 45 mph while it's in 6th gear and low rpms?

[@masadepatrickzubes4393]

How long dose it take you to complete this task?

[@sstressfl]

Knowing what I know now, it would probably take 2 hours. But I usually don't work against a clock.... I just do until its done :)

[@lweston71]

I haven’t watched the whole video yet, But did you straight pipe it? 👍

[@sstressfl]

Impossible! Too complex of a route!

[@herbilanidrik9184]

Good job😂😂😂

[@sstressfl]

thank you 🙏😃

[@macbirt56]

Did Jesus help you really?

[@sstressfl]

Oh yes in so many ways. Not just with this project 🙌 He called my name on May 28, 2003 and set me on solid ground. “Rejoice always, pray continually, give thanks in all circumstances; for this is God’s will for you in Christ Jesus.” ‭‭1 Thessalonians‬ ‭5‬:‭16‬-‭18‬ 🤗 Every breath I take is because of Him and what He did for me on that cross my friend.

[@MochilerosRastreros]

Why you did not weld the part instead of use clamps? just curious

[@sstressfl]

I thought about it. Welding is best for sure. But I was worried that I might need, someday, to take it back off and replace it again. The factory pipe is still very solid but this flex pipe section is vulnerable. I dont think we'll still have the van in the near future, but if we do, I want to be able to service that section again.