Exhaust coupler help please.

[Wightsparks]

Following the sad demise of my Voyager I just acquired a 03 Hyundai Santa Fe - pretty indestructible by all accounts. I got a good deal on it as the exhaust was blowing slightly - despite the PO's garage slapping half a kg of spooge around it.
Basically the pipe that connects the mid silencer to the cat has corroded at the cat - a fairly simple fix if I can get the Cat off- and that is the problem. The cat has this odd connection at the engine side. There is movement in it so I am guessing some sort of O ring assembly but I don't want to hit it too hard or go mad with a screwdriver in there in case it is a quarter turn or it does not come apart. Certainly not putting any penetrating oil in it as I don't want to buy a new cat!
I can not find any pics that include this part - they all have a flexi coupling there instead. (rusty section goes to the cat)
Any clues on how to get it apart please.

 

[frank horton]

there's a place on line for complete exhausts........I bought a system for my Izusu Trooper 3.0..it came with everything inc mountings and clamps..seem to remember it wasn't trhat expensive........
at least the whole lot was just a bit more than the rear box (which was shot)......fitted perfectly........sorry didn't keep the address but think it may have need thru the Bay of Flea's........
worth a try.........

 

[CompoSimmonite]

Looking on line the Hyundai parts diagram shows the section is one piece and not seperate components

I'd remove the whole section from manifold backwards to do the repair.

 

[colnerov]

Hi, I agree with Compo it's not designed to come apart it's probably a ball and socket affair.

Colin

 

[Ton-up]

Cut it off and use something like these...

https://www.ebay.co.uk/sch/i.html?_...xhaust+flexi.TRS0&_nkw=exhaust+flexi&_sacat=0

My mums had an '03 Santa Fe since new. Its been fantastic, only done 60,000mls, but done nothing to it other than servicing. Towed their caravan all round the country too.
Had a couple of re-calls on them, one was after 10 years for corrosion on trailing arms, which Hyundai replaced free and replaced the rear shocks as well. Worth seeing if they have been done.

 

[normspanners]

Cut it off and use something like these...

Thats what I would do but your link takes to the whole page
these https://www.ebay.co.uk/itm/Exhaust-...823364?hash=item4a9ecd2104:g:w48AAOxy1klRbAVD
they are weld ons generally better than clamp ons

 

[Wightsparks]

err... thanks but that bit is not the problem!

The pipe has broken off the cat, between the cat and silencer box ( middle dwg in the in the system layout found by @CompoSimmonite ). I was hoping to undo the bit in the pics but if it is not meant for undoing then I will have to unbolt from the engine resonators which is a bit more involved.

Here is a picture of the fine "repair" done by the garage - though I can imagine they were quoting for a full replacement system hence the lowered price!



There is not much to hang on to at the cat so once I get it off, I'll weld a stub with a slip fitting on the other end to the cat, shorten the broken bit and re-assemble with a clamp.

Thanks @Ton-up I noticed a letter about that recall in the service info so I assume it has been done - also nothing came up on the Gov recall checker.

 

[Ton-up]

I realised what you meant, I thought you wanted to splt the exhaust at that point to repair the cat.

 

[Wightsparks]

Took a while but removed the section from the manifold back. Cleaned up the cat - not much to weld to!


So I sliced a bit of pipe and sleeved it



Then welded a section of new pipe on ready for a joining section I have coming tomorrow.