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Exhaust work 96 Legacy wagon


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2.2, 96 legacy wagon, (non outback)  AWD

 

Flange broke on the resonator (long) pipe.

 

So I get a new one from rock auto  gasket, do nut ring.. springs and bolts.

 

I forgot that the exhaust all came off a 95 model. 

 

Anyway I went to put on the donut ring on the back of the rear catalytic converter only to find that its about 1/4 / 1/8 "  to big on the ID.

 

I cant get the spring bolts to reach the flange on the catalytic converter,,    BECAUSE  previous owner put an after market bolt on flange on the catalytic converter,, which makes the distance between flanges at least an inch further.

 

I used some regular bolts to tighten the flanges together,,  Still leaks around the donut.

 

Im taking it to local yokel exhaust shop and have them fix it 

 

Any idea why every place I tried still gives me a part number for the  cat do-nut which is too big.  ?   It doesn't fit around the catalytic tail piece snugly.

 

Gonna cost me some money but I don't have a welding rig or the want-to  to put another flange on the cat.   

 

The muffler piece flange is so corroded away it leaks as well,, even though I have  a new gasket on there.

 

Just wondering what im doing wrong.

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All the aftermarket donut gaskets are like that.

Have to get it from the dealer to get one that fits properly.

 

With the dealer donut gasket your leak will probably be fixed. The dealer gasket is like half graphite/lead so it conforms to the imperfections better than the aftermarket cheapo steel wire donuts. Lasts a lot longer too.

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I used to have the walker part # that fit these. I ran into this myself and had to actually measure everything and find the right donut gasket. They do make them, but your local parts store is not going to be able to find you the right one at least in my experiance.

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Edit: I had wrong year

Part #31697 walker

 

https://www.rockauto.com/catalog/moreinfo.php?pk=2993826&cc=1269873&jnid=397&jpid=11

 

Just reread 95 has a different part number

Part# 31357 walker. That may be the problem 95 has a different size gasket so your flang is wrong for the 96 part #

Edited by mikaleda
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