What is the muffler corrugation for and how to change it

Replacement and repair of muffler corrugations. Instructions, photos, videos

The exhaust system is one of the most important in a car, providing the necessary traction characteristics of the vehicle, its environmental friendliness and a comfortable level of vibration from engine operation.

The corrugation is an integral part of the exhaust system and serves to dampen vibrations of the operating power unit. It is subject to high mechanical loads and is located in a place under the bottom of the car where there is a risk of damage when hitting an obstacle that rises above the road surface.

In addition, the corrugated element burns out over time and begins to leak gases, creating a high noise level.

Basic methods of replacing muffler corrugations

The corrugated part in the muffler system cannot be repaired or restored, and if it fails, it only needs urgent replacement.

There is no point in delaying the replacement of a defective unit, not only because of the discomfort arising from the irritating sharp noise when the engine is running and the appearance of the smell of exhaust gases in the cabin.

This must be done without delay, so that the entire exhaust system does not crumble and more expensive repairs are not required.

Often in auto repair shops, corrugation is mentioned as the cause of a malfunction in the exhaust system of a car.

Before installing a new corrugated coupling, you need to dismantle the old one, which is welded on both sides to other parts of the exhaust system. This means that it needs to be cut off with a grinder and a new one installed in its place.

In this case it is necessary to ensure:

reliability of fastening;
tightness of the connection;
preservation of the geometric parameters of the exhaust system.

There are several ways to attach a new corrugation:

welding;
tie with clamps;
threaded connection.

The muffler corrugation is subject to breakdowns more often than other parts of the exhaust system

To do this you need:

Place the car on the inspection hole.
Impregnate a regular medical bandage (preferably elastic) with epoxy resin.
Wrap it tightly around the damaged part of the exhaust system.

Replacing corrugations using clamps

Before you start replacing the damaged corrugation with your own hands, you need to purchase a suitable replacement part. To do this, it is necessary to measure its length and the diameter of the connecting pipes. The length of the new part should be 50–60 mm longer than the distance between the existing seams, and the diameter should be slightly larger (0.5–1 mm) than that of the exhaust system pipes.

If there is any malfunction, it is not always possible to contact a car service center

The procedure for performing work to replace the corrugation is as follows:

Place the machine on the inspection hole.
Remove the section of the muffler exhaust duct with the damaged corrugation.
Use a grinder to cut off the defective part on both sides, as close as possible to the existing seams.
Clean the cut areas.
Make longitudinal cuts on the connecting pipes of the new part to make it easier to put on the pipes and to ensure a tighter tightening of the clamps. All cuts and stripping areas must be treated with sealant.
Place the corrugation and press it with clamps, without tightening it too much, so that the correct location of the exhaust pipe can be adjusted in place.
Install the assembled structure on the car, first replacing the gaskets on the flanges.
Check the system for distortions and finally tighten the clamps.
Treat the joints with sealant or prime them.

Replacing corrugations using a threaded connection

The algorithm for performing work when replacing a muffler corrugation without welding, on a threaded connection, is similar to that used when connecting with clamps. The only difference is in the method of fastening the part itself.

What you will need:

Place a new corrugation on the muffler pipes.
Drill holes in the pipe on one side with a diameter of no more than 6 mm, in the amount of 6 to 8 pieces (depending on the diameter of the pipe).
Use a tap to tap the threads in the holes and secure the part with bolts. First you need to thoroughly lubricate the holes and bolts themselves with sealant.
The structure, assembled but not secured along the second pipe, needs to be installed on the car and it is necessary to mark where the edge of the corrugation pipe should go so that there is no distortion.
Remove this section of the exhaust system again and, after drilling holes in the second pipe, secure the part with bolts.
Install the structure on the car.

Source: https://neauto.ru/zamena-i-remont-gofry/

What is a muffler corrugation and how to replace it?

Periodically, depending on the degree of use, an audit is carried out not only of the lubricants and filter elements of the car, but also of its exhaust system. But a lot depends on the state of the last component, including traction characteristics, environmental friendliness, and the level of vibrations.

Why do you need a corrugation on a car muffler: features and tasks

Although this unit performs auxiliary functions as an elastic ligament, without its participation a modern car will not meet the basic conditions of comfort and reliability of the exhaust system. Using a corrugated element, the exhaust pipe is connected to the exhaust pipe of the muffler.

The location and operating conditions of the unit are such that replacing the corrugation on the muffler may be necessary both when hitting obstacles and after a certain number of heating cycles. The time interval between repairs depends only on the quality and design of the braid, which can be two- or three-layer.

The main objectives of a flexible connection are as follows:

elimination of vibration coming from the internal combustion engine to the components of the exhaust structure;
ensuring unhindered longitudinal movements of the power plant;
preventing premature failure of exhaust tract elements.

It must be remembered that the number of corrugated elements depends on the design features of the car brand. For example, an inline 4-cylinder engine has one muffler corrugation, but a V6 has two as standard. However, there are exceptions: one flexible connection is placed after the exhaust manifold, and the second after the catalyst.

Possible causes of corrugated joint failure and its symptoms

This unit has few breakdowns: the connection either breaks due to age and mechanical stress, or begins to partially leak exhaust gases. However, there may be several reasons leading to the listed malfunctions :

failure of the catalyst - clogging leads to increased temperature and pressure in the area of the corrugated connection;
the unsatisfactory condition of the shock-absorbing cushions of the power plant and the muffler fastening elements do not provide the required range of movement of the flexible connection;
deformations from impacts on the road surface;
unqualified connection installation;
exposure to chemical reagents used on roads to de-ice ice;
the presence of additives in the fuel that increase the octane number.

Extraneous noise under the hood during engine operation is the first sign that the corrugation on the muffler needs to be replaced , and complete destruction of the flexible connection may be accompanied by a characteristic deafening sound. A secondary factor indicating a breakdown of this unit is the presence of the smell of exhaust gases in the car interior.

Experienced motorists note a malfunction of the corrugated connection with a significant loss of power, especially on modern brands of cars. This is due to incorrect operation of the oxygen sensor built into the exhaust system. In any of the above cases, it is necessary to replace the faulty element in order to prevent vibration from destroying the entire exhaust tract.

How to replace corrugations on a car muffler

Taking into account the design features of this unit, its repair is impossible - only a complete replacement with a new one. When choosing an analogue, you should take into account such indicators as :

diameter;
number of layers of corrugated element;
part length;
the presence and number of layers of protective braiding;
manufacturer.

Experience shows that cheap corrugation for a car muffler will not last long. The cost of the part depends on the indicators listed above. The quality of the flexible connection for diesel engines is subject to increased requirements, since the vibration level here is higher than that of gasoline internal combustion engines.

The repair process consists of cutting out the faulty component and welding in a new one. This requires disassembling the bolted connection between the secondary pipe and the exhaust manifold.

At first glance, a simple operation can turn into a living hell - limited space and oxidation of the metal on the bolts do not in any way contribute to comfortable work.

During the work, it would be a good idea to pay attention to the catalyst, since its condition may cause the connection to fail.

Also, do not forget about the upcoming welding work, which not everyone can perform efficiently. Therefore, you need to compare the amount of work with your capabilities in advance - it may be easier to turn to experienced craftsmen.

Source: http://autoclub.su/gofra-na-glushitel/

Do-it-yourself repair and replacement of muffler corrugations

The muffler corrugation is an important component of the exhaust pipe, without which the engine exhaust system will not be able to function normally. Most corrugation faults can be repaired yourself.

Corrugation (from the French gaufrer - folds, patterns) or vibration compensator is a flexible element that acts as a flexible connection in the exhaust system.

Outwardly, it looks like an elastic tube with metal weaving in the form of a multilayer mesh and is an intermediate link between the exhaust pipe and the exhaust pipe of the muffler.

Corrugation is often used as a substitute for a section of a burnt-out exhaust pipe.

Due to its design, the corrugation not only compensates for the vibration that accompanies engine operation, but also dampens vibrations that occur when the car starts.

Corrugation is an elastic tube with metal weaving in the form of a multilayer mesh

The corrugation design can be very diverse. It can consist of two or three layers, and also have a single or double reinforced braid. In any case, the corrugation is made of durable stainless steel.

Despite its strength, the corrugation is quite sensitive to mechanical damage and is subject to wear.

The exhaust system is always subject to wear and tear and is highly vulnerable, as it is located under the bottom of the car. Faulty corrugations cause a lot of problems for car enthusiasts.

The causes of corrugation malfunction may be:

blows;
clogged catalyst;
influence of exhaust gases;
metal rotting due to mud deposits;
wear of engine mounts;
wear of the muffler mounting rubbers.

It is very difficult to protect the corrugation from the influence of all these factors. Some car enthusiasts make and install metal protection on the corrugation, which prevents crushed stone from entering the exhaust pipe area.

With everyday and intensive engine operation, the exhaust system from the inside gradually becomes clogged with deposits and carbon deposits. First of all, the catalyst is susceptible to this. When the catalyst is clogged, if the corrugation is installed in front of it, exhaust gases accumulate, creating strong pressure, leading to rupture of the corrugation.

The walls of the corrugation cannot withstand the pressure load of the exhaust gas, and a rupture occurs

The corrugation may burn out. This occurs after prolonged continuous use of the vehicle and is a “standard” corrugation failure. It is important to understand that due to poor-quality fastening of the exhaust pipe, the corrugation can burn out very often.

For example, if the exhaust system is mechanically damaged, the corrugation may stretch or bend. In this case, its fastenings will be displaced, and the burnout will become chronic. Replacing the corrugation will help solve this problem only for a while. Therefore, before repair or replacement, the entire exhaust system must not deviate from the mounting points.

The temperature and chemical composition of the exhaust lead to burnout of the corrugation

Corrugation repair

You can replace the corrugation at almost any car service center. The cost of work varies from 2 to 5 thousand rubles. depending on the make of the car and the type of exhaust system. It takes no more than half an hour. Specialists usually do not undertake to repair corrugation. Therefore, you have to put it in order yourself.

Temporary repairs

In case of minor damage, it is sometimes necessary to bring the corrugation into working condition for a while - before replacing it. The only simple way to do this is to wrap the damaged area with durable material, which is used as:

special heat-resistant tape;
fiberglass fabric;
medical or elastic bandage.

In addition, you will need:

two or three metal clamps;
epoxy resin;
latex gloves;
screwdriver.

During the repair process, the following actions are performed.

The car is installed on the inspection hole.
Access to the damaged corrugation is provided.
The area to be wrapped is cleaned.
The wrapping material is impregnated with epoxy resin and placed on the damaged area.
The winding in two or three is secured with clamps.

For temporary repairs, the damaged area is wrapped with durable material.

It is not recommended to use the car for 24 hours to cure the epoxy resin. After such repairs, the corrugation will last another two to three months.

Replacing the corrugation yourself is quite simple. To do this, it is enough to have a garage with an inspection hole or a lift and a standard set of tools.

Choosing a corrugation

The choice of corrugation should be taken responsibly. It is advisable to buy it from trusted sellers.

Depending on the type of exhaust system, corrugations are distinguished:

vertical;
horizontal.

A vertical corrugation is installed under the exhaust manifold and works for compression. When the engine is running, it does not bend, but contracts and straightens vertically. Such corrugations have a length of about 150 mm and a diameter of 65 mm. When purchasing, a corrugation with the appropriate dimensions is selected.

The vertical corrugation is made of durable and elastic alloys, which allows it to stretch in length

The horizontal corrugation is located below the first elbow of the receiving pipe and bends. It reaches 400 mm in length and 65 mm in width. When choosing such a corrugation, you should take into account the way it is connected to the exhaust pipe.

Horizontal corrugations are installed on most cars

When replacing, it is recommended to first cut out the faulty corrugation and measure the distance between the two pipes. Only after this can you select a new corrugation.

Any corrugation is installed on the pipe with an overlap of 10–20 mm. Therefore, the new corrugation should almost always be longer than the old one, at least 20–30 mm. In addition, the geometry of the exhaust pipe is taken into account - the new corrugation may not fit into the space between the pipes or noticeably change the angle of inclination of the pipe. The latter can lead to incorrect operation of the exhaust system.

The corrugation should not have bends, and the weld should be more dense

Replacing corrugations using electric welding

Before installing a new corrugation, you need to properly disconnect the old one. To work you will need the following parts:

a new gasket installed between the manifold and the exhaust pipe;
muffler mounting rubber bands;
bracket for fastening the exhaust pipe (if such a mount is available);
O-rings.

Dismantling the corrugation is carried out in the following order:

The bolts securing the exhaust pipe and manifold are unscrewed.
The rubber bands securing the muffler are removed.
The other exhaust pipe fasteners are disconnected.
The corrugation is cut off using a grinder.
The remains of the old weld are removed.

After this, they “try on” the new corrugation. This is an important procedure, since bends and kinks should not be allowed.

After installing the new corrugation, all fasteners should fall into place, and the corrugation itself should not change its geometry

The two parts of the pipe are connected by corrugation (overlapping the pipe), and the entire system is installed in place.
The connection points of the corrugations are secured by electric welding.

For high-quality welding, 2–3 mm electrodes are used. The best results are shown by argon-arc welding with a non-consumable tungsten electrode with a stainless wire additive.

When installing the exhaust pipe, the corrugation must be “grabbed” by welding in several places
The corrugation is fixed in the desired position by a welding machine at two or three points around the circumference of the pipe.
After this, the entire pipe is again removed from the fastenings and carefully welded on the ground with a continuous seam. To protect against stones while moving, a protection can be made and welded onto the corrugation

Video: replacing a muffler corrugation using welding

After welding work, the gaskets, O-rings and rubber bands for attaching the muffler are changed, and the muffler assembly is installed in place.

Replacing corrugations without welding

The corrugation can be replaced without using electric welding. For this you will need:

grinder or hacksaw;
clamps (48 mm is enough);
screwdriver.

According to the above algorithm, the old corrugation is removed. When attaching the new corrugation with clamps, two small cuts are made on both sides to secure it more securely. Then the corrugation is pulled over the pipes and clamped at the edges with clamps. After this, the exhaust pipe is installed in place.

After installing a new corrugation, the clamps should be periodically tightened

According to reviews from car owners who have carried out repairs in this way, the design is reliable and lasts quite a long time.

Thus, removing the old one and installing a new corrugation with your own hands is quite simple. Even if you were unable to find a welding machine, all work can be done without welding.

Source: http://autozam.ru/remont-i-obsluzhivanie/zamena-gofryi-glushitelya.html

Do-it-yourself repair and replacement of muffler corrugations: what is it for, which one to choose when replacing, how to repair without welding

The design of a vehicle muffler is relatively simple.

At the same time, there are basic elements and there are additional parts that can have a certain impact on the operation of the entire exhaust system.

Thus, the corrugation (or elastic connection, or lambda corrugation) refers to those parts of the muffler on which the comfort and safety of driving depends. But drivers do not always pay the necessary attention to this element.

The corrugation (or a special connection in the exhaust system) plays an important role in the removal of exhaust gases from the car. Today, almost all models of foreign cars are equipped with corrugations on muffler pipes. They have the shape of a barrel and are designed to act as an elastic connection between pipes to reduce vibrations and noise.

The element loses its metallic luster over time, but continues to protect the exhaust system from excessive vibrations

This element in the exhaust system serves for:

more reliable connection of two pipes to each other;
reduction of vibration currents that come from a running engine;
damping vibrations when starting the engine.

That is, roughly speaking, if there is corrugation, all parts of the exhaust system will work for a long time, since they will not be subject to strong vibrations.

What does corrugation consist of?

Depending on the make and model of the car, the elastic connector can be made according to different patterns. Traditionally, this is a barrel-shaped element that has two or three internal layers, and is also equipped with a double (less often single) braid.

This model has two internal protective layers and one layer of braid

If you look at the structure of this part in section, it will look like a tube that has both internal and external protection made of stainless steel. The protective layer allows you to minimize vibration currents from the exhaust manifold, due to which the muffler pipes are less susceptible to destruction. However, the corrugation itself, due to the fact that it takes the “blow”, is destroyed quite quickly.

If we compare the service life of the corrugation and other elements of the exhaust system, then it is the one that fails the fastest. It is subject to ruptures due to strong vibrations, however, cracks are most often observed after mechanical shocks.

So, the most common causes of malfunctions can be considered:

Braid ruptures after mechanical shocks.
Wear of the muffler rubber bands, since the suspensions can no longer ensure a fixed position of the pipes under the body.
A clogged catalyst is one of the most common causes of failure. If the catalyst is clogged, then the exhaust cannot escape from under the car, but breaks the corrugation.

The driver can determine the occurrence of malfunctions without inspecting the muffler. Firstly, you will hear a sharp roar and loud noise while driving. Secondly, the smell of exhaust will appear in the cabin. In addition, the car's power will be reduced when starting from a standstill or overtaking.

Corrugation burnt out - what to do

Burnouts are a common problem for all muffler elements. The burnt-out part does not perform its functions, moreover, it leads to driving discomfort and can even pose a danger to the driver.

https://www.youtube.com/watch?v=AZT5CK0dGBM

Unfortunately, not a single corrugation can be completely repaired, so there are only two options for eliminating a burnt-out element:

Change along with the pipe.
Change separately, leave the pipe the same.

The photo shows how severely the corrugation was deformed due to burnout

Car enthusiasts prefer the second option, as it is the least expensive:

Breaks and cracks in the braid

In most cases, you can fix this problem yourself. So, if the braid is double, and there is damage only on the upper protective layer, you can restore the functionality of the product:

A new one is pulled over the old corrugation.
As a new one, you can even use heat-protective elastic materials that are sold in car dealerships.
The main thing is to securely secure the new coating using welding, metal clamps or even heat-resistant glue.
The new coating will protect the device from further ruptures and will contribute to its long service life.

Due to poor quality fastening, the corrugation breaks at the joints with the pipe

Due to the tightness of the product itself, repairs in case of severe ruptures and burnouts are not possible. However, in some situations you can save on buying a new part of the system and repair the device yourself.

Temporary measures

The key to successful operation of the exhaust system is its complete tightness. The same applies to corrugation. In order to quickly eliminate the deformation that has begun, you can use special sealants for mufflers. These substances perfectly close all holes or cracks, ensuring tightness even at the highest temperatures.

Bandaging

Temporary repairs also include the use of bandages. A special bandage tape made of thin foil is applied to the pipe. The tape covers cracks and holes, allowing you to ride this muffler for some time:

Heat-resistant material allows you to extend the service life of the corrugation for some time

How to weld using electric welding

Self-repair using a welding machine is possible if you have experience in welding. If the car owner is not confident in his abilities or has only basic skills, then it is better not to take risks, as it is easy to damage the muffler pipes.

Sometimes, after hitting an uneven road, the corrugation may “move away” from the pipe - in this case, it is necessary to weld it again. For these purposes, two types of electrodes are usually used - with a diameter of 3 and 4 mm:

The corrugation is grabbed along the diameter of the pipe with a 3 mm electrode.
The correctness of its fixation is checked (the product must be located strictly in the center of the pipe).
Next, the entire circumference of the pipe diameter is welded with 4 mm electrodes.
After the weld has cooled, it is necessary to clean it and paint it with heat-resistant paint.

The seam when welding corrugation must be smooth and uniform

Replacement procedure

When replacing the corrugation yourself, you will need to find a suitable element in advance. Very often, car owners cannot find an element of the required diameter and length. However, there is no need to look for a product with the same dimensions as the old one. Any corrugation that is no smaller in size than the old one will do.

In addition to cheap single-layer devices, there are two more types of these products:

the first is called “interbraid” - it has three layers of braid at once, which extends the service life of the corrugation for a long time;
the second is called “interlock” and has four layers - three on the outside of the tube and one thick one on the inside.

Accordingly, when choosing corrugation for your car, you need to focus on the quality you want to receive. You can buy a single-layer product and after a few years carry out the replacement operation again. Or immediately spend money on “interlock” and forget about this problem with mufflers forever.

How to remove the corrugation from the muffler

The easiest way is to dismantle the element together with the exhaust pipe. In this case, it will take less time, and it will be easier to change the product:

It is best to drive the car onto an inspection hole or overpass - that is, it is necessary to provide free access to the muffler pipes.
Unscrew the nuts from the exhaust manifold studs and disconnect the exhaust pipe from the manifold.
Then remove the pipe from the rubber hangers.
Next, unscrew the two bolts at the connection between the exhaust pipe and the resonator.
Then pull out the exhaust pipe with the corrugation from under the car.
The old element can only be removed using an angle grinder (grinder). In this case, you need to cut the corrugation only along the weld seam itself, so as not to damage the pipe walls, since it will still be needed.
Welding residues from the pipe can be removed with a hammer and chisel, because it is necessary to level the surface before installing a new corrugation on the pipe.

Video: how to remove the corrugation from the muffler

Replacement without welding

Usually car owners simply weld the element in place of the old one. However, not all drivers have a welding machine at hand. It is much easier to install the corrugation on the pipe using metal clamps - no welding is required, and then it will be easier to remove this element if necessary.

The operating procedure is as simple as possible:

A new corrugation is installed on the exhaust pipe.
It is attached to the pipe as rigidly as possible with metal clamps.
The joints of the connections are treated with heat-resistant sealant.
The exhaust pipe is fixed in its place in the muffler system.

Video: changing the corrugation in the garage with your own hands

The corrugation helps extend the life of the car muffler. If the old part of the muffler has become unusable, then you don’t have to replace it with a new one - you just need to cut off the remnants of the braid and move on. However, any driver will immediately be able to feel the difference between driving with and without corrugation.

Source: http://motorltd.ru/zamena-gofryi-glushitelya/

Instructions on how to replace the muffler and corrugation yourself

Reasons why corrugation most often fails:

Clogging of the catalyst device occurs as a result of the car owner not cleaning the unit. Due to a clogged outlet, the pressure in the system increases, which transfers to the corrugation. This contributes to its rupture in the thinnest place.
Corrosion of corrugation as a result of exposure to exhaust. This problem occurs when the power unit cushions are damaged. Corrosion may be a consequence of drying out or deformation of the rubberized elements for fixing the internal combustion engine.
Getting crushed stones or other small particles into the exhaust pipe while driving. As a result of exposure to chemical reagents used to treat the road surface in the cold season, burnout occurs. Such substances quickly corrode existing defects.

Signs by which a malfunction can be identified:

uncharacteristic sounds from the exhaust pipe, similar to sneezing;
drop in car engine power;
the operation of the power unit has become unstable;
exhaust gases entering the vehicle interior;
formation of soot on metal components.

The channel “Made in a Garage” talked about malfunctions of corrugations in cars.

Replacing corrugations

Changing the corrugation without welding will not work. You can fix the device on clamps if there is no welding equipment, but such fastening will be unreliable.

What you will need

Items that will be required for replacement:

rubber parts for exhaust pipe clamps;
welding machine;
Bulgarian.

Step-by-step instruction

Algorithm of actions for performing replacement:

The nuts located on the studs of the collector device and the connections on the back side of the pipe are unscrewed.
The receiving line is removed, and the old vibration compensating device is cut off using a grinder. When performing the task, you must be careful to remove only the weld seam. The grinder must not touch the flange and the pipe itself. If the corrugation is located under the collector device, these parts can be hooked.
If some of the welds cannot be removed, their removal is done manually. For this you will need a chisel.
The components of the receiving line are prepared, the parts are installed in the landing site and the rubber elements are replaced. When installing the corrugation, you need to make sure that no excess stress will accumulate on it. The element must not be compressed or stretched. Bends are also not allowed.
When the receiving components of the device are secured, a new corrugation is installed and secured by welding. Then the receiving line is removed and the corrugation itself is welded around the perimeter.

Cutting off the old corrugation Installing and welding a new one

Muffler malfunctions

The need to completely replace the muffler may arise due to the following malfunctions:

The inside of the device is regularly exposed to hot gases. This leads to premature wear of the muffler, as well as the formation of erosion. When the power unit is idling and overheating, the gases that remain inside are cooled too low. This promotes the formation of condensation, as a result of which corrosion appears on the metal and it collapses.
From the outside, dirt gets onto the body of the device when moving, and in the cold season - ice. Regular exposure to moisture and dirt leads to rapid wear. If the driver drives carelessly, constant impacts of the exhaust pipe on the ground will cause damage. The seal of the housing is quickly lost.

How to troubleshoot a muffler?

The best solution to the problem would be to replace the muffler yourself. But the device must be replaced after it could not be repaired.

The repair procedure may consist of using a bandage that is made from high-temperature tape. It is wrapped around the damaged section of the exhaust pipe.

The tape itself is usually made of fiberglass and can withstand severe temperatures; for better fixation, silicate or epoxy resin is added to the material.

The damaged area with the defect is wrapped with tape, and when it hardens, the pipe must be painted. For this, heat-resistant paint is used. Repair may involve replacing the reinforced gasket located between the intake line and the muffler itself. When replacing this element, it must be installed in a similar position.

How much does it cost to replace a muffler?

On average, replacing a muffler costs from 1000 rubles, depending on the car model.

Prices using the example of the Bibizon company https://bibizone. ru:

Name	Price, rub
Replacing the muffler corrugation	from 3000
Muffler tuning	from 2000
Muffler installation	from 3000
Muffler repair	from 1000

Video “How to change a muffler”

The Mir Matizov channel spoke in detail about replacing the muffler in a car.

Source: http://AvtoZam.com/dvigatel/vypusk/zamena-glushitelya-svoimi-rukami/

Replacing the muffler corrugation

The corrugation as part of the exhaust system is an elastic metal-ceramic coupling embedded in the muffler pipes.

For modern cars (especially foreign cars), corrugations are a basic design part - especially necessary for diesel engines that create significant vibrations (compared to gasoline engines).

But even if corrugations are not provided for in the factory design, they can be installed additionally to reduce noise in the cabin and increase the operating comfort of the car.

Car exhaust system corrugations, exhaust corrugations, etc.

Corrugations (or several corrugations - separately for each exhaust system pipe) are designed to “decouple” the engine and exhaust system from vibrations. When the engine is running, vibrations are transmitted to the body through the muffler pipe mounting brackets. In this case, the elastic corrugation effectively dampens vibrations, helping to significantly reduce the noise level in the car interior.

The most characteristic sign of a malfunctioning muffler corrugation is increased noise when the engine is running .

Another sign may be a characteristic “metal on metal” knock in the front of the car (under the hood - from the engine exhaust pipe). At high engine speeds, such a knock turns into a sharp rattling sound.

A side effect of a corrugation malfunction is a decrease in engine thrust , an increase in fuel consumption (although these “symptoms” can be caused by other reasons - not necessarily a corrugation malfunction).

Repair of the muffler corrugation is not expected - only replacement. Modern cars (especially foreign cars) are characterized by a complex exhaust system, where the corrugations can be adjacent directly to the exhaust gas catalytic converter. Therefore, the selection of the required spare part must be carried out with special care - for a specific car model.

An additional difficulty is attaching the corrugation to the muffler pipes - using welding. Which, given the dense “packing” of modern engine components, creates certain problems.

When replacing the corrugation, additional operations may be required to disassemble “neighboring” units (for example, removing the air filter to access the mounting bolts).

All work must be performed on a lift.

Simplified, the procedure for replacing the muffler corrugation of a foreign car looks like this:

removal of the unit from the car (or partial removal on a lift) - to simplify welding work;
since the muffler elements under the bottom of the car are always dirty, to easily unscrew the fastening bolts it is better to use special “softening” compounds (“liquid wrenches”);
cutting off the old corrugation from the muffler pipe (you will need a grinder and considerable caution!);
Before cutting off the corrugation, it is necessary to mark the center line of its location ;
cleaning the old weld;
installation of corrugation (it is not recommended to weld parts end-to-end; it is better for the corrugation to be slightly larger in diameter and overlapped );
welding of new corrugation according to the applied marks;
processing of the weld – to protect against possible corrosion;
installing the muffler pipe with corrugation back onto the car.

It should be noted that the price of the service for replacing the muffler corrugation usually does not exceed 3,000 rubles. While independent “experiments” with a car - without the proper experience and professional tools - can result in significant costs - for example, replacing an expensive catalyst (catalyst costs from $500)

The exhaust system corrugation is relatively durable. Therefore, its replacement is required less often than, for example, muffler exhaust pipes. However, when performing work to replace the corrugation, it would be a good idea to check:

condition of the gaskets between the exhaust pipe and the cylinder block
condition of gaskets on the flanges of the exhaust pipes of the muffler
catalytic converter condition
operability of the oxygen sensor (“lambda” probe)
the condition of the engine mounts (the cause of increased vibrations may be in them, and not in damaged corrugations!)

Used corrugations can be used as a “template” for more accurate selection of the dimensions of a new part.

During operation, the corrugations of the exhaust system are exposed to alternating loads (vibration, compression, bending), as well as the destructive effects of high temperature and chemically aggressive exhaust gases.

However, most often, the corrugation requires replacement at an unpredictable interval of time - due to destruction from external influences (for example, an impact on an obstacle or increased vibration of the engine or gearbox - with significant wear of their supports).

Traffic regulations prohibit operating a vehicle with a faulty exhaust system!

Untimely replacement of the muffler corrugation leads to increased exhaust noise and the appearance of an unpleasant knocking sound in the engine compartment. For the engine control system, a faulty corrugation is a possible source of problems with mixture dosing.

After all, if the corrugated pipe in front of the exhaust gas catalytic converter has a “hole,” air leaks and incorrect oxygen sensor readings are possible.

As a result - a command to enrich the fuel-air mixture (the engine controller will “decide” that “too much air - not enough fuel”), an increase in fuel consumption, provoking carbon deposits on engine parts and the risk of failure of the converter , which is very sensitive to enrichment of the mixture and excess unburned fuel in the exhaust gases!

As a rule, any corrugation is placed on the pipe “ overlapping ”. If it is possible to cut off the corrugation without damaging the pipes inserted into it, the new corrugation should be the same length as the old one. If you have to cut the muffler pipes themselves, the new corrugation should be selected with a margin of length (by 20-30 mm ).

Depending on the design of the exhaust system, the corrugation can be installed either vertically (immediately under the engine exhaust manifold - in front of the exhaust pipe of the muffler) or horizontally (after the first “elbow” of the exhaust pipe).

In the first case, the corrugation works in compression (but not in bending), its length usually does not exceed 150 mm (inner diameter - no more than 65 mm ), and the structure is reinforced. When replacing such a corrugation, the new part must be of identical size!
In the case of horizontal installation, the corrugation is mainly subjected to bending load. Its length can reach up to 400 mm, and its diameter up to 65 mm . When installing such corrugation, special attention should be paid to the quality of the weld.

If incorrectly into the exhaust system between the engine and the exhaust system will increase to wear of the muffler suspension parts (price from 3,000 rubles), cracks in the exhaust manifold (price from 5,000 rubles), and failure of the engine mounts (price from 5,000 rubles), etc.

Source: http://pulam.ru/zamena-gofry-glushitelya/