How to Replace Exhaust System on a 04-09 Subaru Outback

How to Replace Exhaust System on a 04-09 Subaru Outback

In this video, 1A Auto shows you how to replace a broken, leaking, clogged or corroded exhaust. This video applies to the 08 Subaru Outback

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Dante Grimm says:

How much different is this process on 2002 subaru outback limited?

Specialized 29er says:

Looks to be a good sturdy system but why those big rear mufflers.

Chackers says:

You can't soak exhaust nuts and bolts for too long.  If you can, let the penetrant work for hours, reapplying every half-hour or so.  Can save LOTS of work.  Remove as much rust as possible with a wire brush, apply penetrant, tap on the nut/bolt a few times, then let it sit.  Repeat every 20 minutes or so, for a couple hours.  Also, when you finally go to remove the nut or bolt, first wipe the penetrant off of it: it's basically a lubricant, which you don't want on the outside, because it makes it easier for the socket or wrench to slip off.  8:54 – new hardware is far preferable, of course, but you CAN reuse these nut, especially when they're readily accessible like these: wire brush the inside threads, grind the rust off of the mating surfaces, and use a lot of anti-seize when reinstalling.  Best, although it's relatively pricey, is to use stainless nuts and bolts.  These Subarus have LOTS of heat shields around the exhaust, most of the fasteners of which are VERY rusty: you'll likely have to cut off the majority of them with a Dremel.  13:30 – unfortunately, the replacement pipe is not only missing most of the heat shielding, but there's nothing to which to attach the old ones to it, even if you wanted.  15:22 – when trying to handle a large part like this by yourself, use a rope or bungee near one end to temporarily suspend it while you work on the other end.  15:33 – I have a tube of silicone gel I use for reinstallation.  16:44 – for this part, you can use a couple smaller bolts to hole the pipes relatively close to their final orientation, then replace each with the spring bolts.  19:05 – I prefer to put the head of the bolt toward the front of the car: that way, the nut end catches a little less road debris.  One thing I realized once I started working on exhausts is that although it appears there's a lot of "wiggle room", there isn't: it's unexpectedly tight for it's size.  20:29 – IF you decide to do such prying, DON'T do it "against" the muffler: instead, remove the muffler, put part of the hanger in a vice, and bend the other part.  Trying to pry it using only the muffler itself as a brace could very well damage the muffler.  Note that here, it appears that the lower part of the hanger is bent relative to the upper part: if the upper part appears bent relative to the muffler, get it replaced, if you can: trying to correct such a bend could, as previously mentioned, damage the muffler.Better yet, though, compare the hangers on the new muffler to those on the old one, then bend as necessary BEFORE installation.  Also, I like this mechanic: she knows what she's doing, and she's articulate.  Thanks for the video!

Ant Green says:

I have a 2008 subaru legacy i think i need a new cat,cant i just cut out the old one and weld a new one on??

Miriam Vivo says:

Have a po448 on a 2006 subaru sti a tuf one to fix

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