How to replace an exhaust clamp

The exhaust pipe is supported by exhaust clamps inside the vehicle. A bad clamp can lead to exhaust leaks that can become dangerous if left uncorrected.

While today's new cars, trucks, and SUVs are filled with bells and whistles that showcase new technology, some mechanical components are still produced the same way they were in the old days. One of the best examples of this is the exhaust system. The exhaust system consists of separate sections connected to each other either by welding or by a series of clamps. In some cases, the car will have a clip attached to the weld point for added support. This is the duty of the exhaust clamp on most cars, trucks and SUVs made since the 1940s.

In many cases, exhaust clamps are used with aftermarket exhaust system parts such as high performance mufflers, headers, or other specialty components designed to enhance an exhaust system. They are used to connect individual parts or support welds in the same way as they are used in original equipment manufacturer (OEM) applications. They come in different shapes and sizes and with unique fastening processes.

Some of them are U-shaped, some are round, and there are those that consist of two hemispherical parts connected in one clip. These clamps are often referred to as V-clamps, lap clamps, narrow clamps, U-clamps, or hanging clamps.

If the clamp is broken, it cannot be repaired in the exhaust system; it will need to be replaced. If the clamp loosens, breaks, or begins to wear, it may fall, causing the exhaust pipe to become loose. This can lead to serious problems such as broken exhaust pipes, which can cause exhaust gases to circulate through the vehicle interior and lead to serious respiratory problems for the driver and passengers.

The exhaust system is mechanical in nature, which means that it is not usually controlled by sensors. The only part of the exhaust system that is controlled by the engine control unit (ECU) is the catalytic converter. In some cases, the OBD-II code P-0420 indicates a leak near the catalytic converter. This is usually due to a loose exhaust system bracket or clamp that secures the catalytic converter to the adjacent exhaust pipes. This error code will be caused by a leak and stored inside the ECU. In most cases, this will also cause the Check Engine light on the dashboard to come on.

If the vehicle does not have an onboard computer that stores these codes, you will have to perform some manual diagnostic work to determine if there is an issue with the exhaust system clamps.

Below are a few physical warning signs or symptoms that indicate there is a problem with this component:

• You hear excessive noise from below the vehicle. If the exhaust system clamp is broken or loose, it may cause the exhaust pipes to separate or crack or hole in the pipes. A broken or loose exhaust pipe usually causes additional noise near the crack, as the purpose of the exhaust system is to circulate exhaust gases and noise through multiple chambers within the muffler to provide a quieter sound. If you notice excessive noise from underneath your car, especially while accelerating, it could be caused by a broken exhaust clamp.

• The vehicle does not pass emissions testing. In some cases, a loose exhaust system clamp can cause the exhaust system to leak. This will result in excessive emissions outside the vehicle. Since most emissions tests involve measuring tailpipe emissions as well as using an external sensor that can measure exhaust leaks, this can cause the vehicle to fail the test.

• Engine misfires or backfires. Another sign of an exhaust leak is the engine revving during deceleration. This problem usually gets worse the closer the leak is to the exhaust manifold, but it can also be caused by a leak from a broken or loose exhaust clamp, especially when recycled.

If you notice any of these warning signs, there are a few things you should do before deciding to replace this part, just to be sure. These include the following:

• Examine the exhaust pipes. If they hang under the car (at least more than usual), the exhaust system clamp may have broken. When the car is securely parked on a level surface and turned off, crawl under it and check to see if the exhaust pipe itself is damaged. If so, you should replace the pipe.

• Listen for extra noise. If you notice a loud noise coming from under your vehicle while accelerating, it is likely due to an exhaust leak. The cause of the leak may be a broken or loose exhaust clamp. Inspect the underside again to make sure the exhaust pipes are not broken or cracked before replacing the exhaust clamps.

• A warning: Exhaust clamps are designed to support the exhaust system, NOT a patch. Some do-it-yourself mechanics will try to install an exhaust clamp to plug a cracked exhaust pipe or an exhaust pipe that is rusty and has a hole. This is NOT recommended. If you notice holes or cracks in any of the exhaust pipes, they should be replaced by a professional service technician. An exhaust clamp may reduce noise, but exhaust fumes will still leak out, which in severe cases can be fatal.

• Attention: The instructions below are general replacement instructions for most exhaust clamps used in OEM applications. Many exhaust clamps are used in the aftermarket, so it is best to seek advice from the aftermarket manufacturer on the best method and location for installing such a clamp. If it is an OEM application, be sure to purchase and review the vehicle's service manual before replacing the exhaust clamp.

Part 1 of 2: Exhaust Clamp Replacement

In many cases, the symptoms of a bad clamp that you may notice are actually caused by cracks or holes in the exhaust system, which, again, cannot be repaired or fixed with a clamp. The only time you should replace a clamp is when the clamp breaks or wears out BEFORE it causes the exhaust pipes to crack.

If your exhaust yoke is broken or worn, there are a few things you need to do before taking on this job:

• Get the right clamp. There are several types of exhaust clamps, but it is very important that you select the correct clamp size and style for your particular application. Refer to your vehicle service manual if you are replacing an OEM clamp, or contact your parts supplier if you are replacing an aftermarket exhaust clamp.

• Check the correct circle. There are several sizes of exhaust pipes, and it is incredibly important that they fit the right size exhaust clamp. Always physically measure the circumference of the exhaust yoke to make sure it fits the exhaust pipe it is installed in. Installing the wrong size clamp can cause further damage to your exhaust system and may result in the need for a complete exhaust system replacement.

Necessary materials

• Flashlight or droplight
• Clean shop rag
• Boxed wrench(s) or set(s) of ratchet wrenches
• Impact wrench or air wrench
• Jack and Jack stand
• Replacement exhaust clamps to suit your needs (and any matching gaskets)
• Wrench
• steel wool
• Penetrating oil
• Protective equipment (e.g. safety goggles and protective gloves)
• Service manual for your vehicle (if you are replacing a clip used in an OEM application)

• Wheel chocks

• AttentionA: According to most maintenance manuals, this job will take about an hour, so make sure you have enough time. Also keep in mind that you will have to raise the car to have easy access to the exhaust pipe clamps. If you have access to a car lift, use it to stand under the car as this will make the job much easier.

Step 1: Disconnect the car battery. Although not many electrical parts are affected when replacing the exhaust system clamps, it is a good habit to always disconnect the battery cables when doing any part removal work on the vehicle.

Disconnect the positive and negative battery cables and set them aside where they cannot come into contact with anything metallic.

Step 2: Raise and secure the car. You will be working under the car, so you will need to raise it with jacks or use a hydraulic lift if you have one.

Be sure to install wheel chocks around the wheels on the side of the car that you will not be jacking up for support. Then jack up the other side of the car and secure it on jack stands.

Step 3: Locate the damaged exhaust collar. Some mechanics recommend starting the car to find a damaged exhaust clamp, but this is very dangerous, especially when the car is in the air. Perform a physical inspection of the exhaust clamps to look for loose or broken ones.

• A warning: If during a physical inspection of the exhaust pipe clamps you find any cracks in the exhaust pipes or holes in the rusty pipes, STOP and have a professional mechanic replace the affected exhaust pipes. If the exhaust clamp is damaged and hasn't broken the exhaust pipe or welds, you can proceed.

Step 4: Spray penetrating oil on the bolts or nuts on the old exhaust yoke.. Once you find a damaged exhaust pipe clamp, spray penetrating oil on the nuts or bolts that hold the clamp to the exhaust pipe.

Because these bolts are exposed to the elements under the vehicle, they can rust easily. Taking this quick extra step can reduce the chance of stripping nuts and bolts, which could result in the clamp having to be cut and potentially damaging the exhaust pipes.

Let the penetrating oil soak into the bolts for five minutes.

Step 5: Remove the bolts from the old exhaust clamp.. Using an impact wrench (if you have one) and an appropriate size socket, remove the bolts or nuts holding the old exhaust collar in place.

If you don't have an impact wrench or air wrench, use a hand ratchet and socket or socket wrench to loosen these bolts.

Step 6: Remove the old exhaust collar. After the bolts have been removed, you can remove the old clamp from the exhaust pipe.

If you have a clamshell clamp, simply pry up the two sides of the exhaust pipe and remove. U-clip is easy to remove.

Step 7: Inspect the clamp area on the exhaust pipe for cracks or leaks in the system.. Sometimes when removing the clamp, small cracks can appear under the exhaust clamp. If so, make sure these cracks are serviced by a professional or the exhaust pipe is replaced before installing a new exhaust clamp.

If the connection is good, proceed to the next step.

Step 8: Clean the clamp area with steel wool.. The exhaust pipe may be rusty or corroded. To make sure the connection to the new exhaust clamp is secure, lightly scrub the surrounding area of ​​the exhaust pipe with steel wool.

Don't be aggressive with the steel wool, just be sure to dust off any debris that will interfere with the connection of the new exhaust clamp.

Step 9: Install the New Exhaust Clamp. The installation process is unique depending on what type of clamp you are using. In most cases, you will use a U-shaped outlet clamp.

To install this type of clamp, place the new U-ring on the exhaust pipe in the same direction as the U-ring from the old clamp. Place the support ring on the other side of the exhaust pipe. Holding the clamp in place with one hand, thread one nut onto the threads of the U-ring and hand tighten until you reach the support ring.

In the same way, install the second nut on the other side of the clamp, being sure to tighten it by hand until you reach the support ring.

Tighten the nuts with a socket wrench or ratchet. Use the progressive tightening method on these bolts to make sure one side is not tighter than the other; You want a clean connection on the exhaust yoke. DO NOT tighten them with an impact wrench; using an impact wrench can twist the exhaust pipe clamp, so it is best to install these nuts with a hand tool.

Fully tighten the exhaust clamps with a torque wrench. You can find recommended torque settings in your vehicle service manual.

• Functions: Many certified mechanics always finish tightening the important nuts attached to the studs with a torque wrench. Using an impact or pneumatic tool, you can tighten the bolts to a higher torque than the set torque. You should ALWAYS be able to turn any nut or bolt at least ½ turn with a torque wrench.

Step 10: Prepare to lower the car. Once you have finished tightening the nuts on the new exhaust clamp, the clamp should be successfully installed on your vehicle. Then you must remove all tools from under the car so that it can be lowered.

Step 11: Lower the car. Lower the vehicle to the ground using a jack or lift. If you are using a jack and stands, first raise the vehicle slightly to remove the stands and then proceed to lower it.

Step 12 Connect the car battery. Connect the negative and positive battery cables to the battery to restore power to the vehicle.

Part 2 of 2: Repair Check

In most cases, checking the car after replacing the exhaust clamp is very simple.

Step 1: Visually inspect the exhaust pipes. If you previously noticed that the exhaust pipes hung low, and you can physically see that they no longer do this, then the repair was successful.

Step 2: Listen for excessive noise. If the vehicle used to make excessive exhaust noise, but now the noise is gone when starting the vehicle, the exhaust clamp replacement was successful.

Step 3: Test drive the car. As an additional measure, it is recommended that you road test the vehicle with the sound off to listen for noise coming from the exhaust system. If the exhaust clamp is loose, it usually creates a rattling sound under the car.

Depending on the make and model of the car you're working with, replacing this component is pretty straightforward. However, if you have read these instructions and are still not 100% sure about doing this repair yourself, if you simply prefer to have a professional handle your exhaust system for you, or if you notice cracks in your exhaust pipes, contact one of the certified mechanics at AvtoTachki to complete the exhaust system inspection so they can determine what is wrong and recommend the correct course of action.