How do I replace an exhaust hose?

[perry386]

This hose that runs from the exhaust manifold into the muffler blew out the other day and there is now a big hole in it. Nautique parts sells the hose but I have no idea how to replace it. It looks like I will have to unscrew the top part of the manifold. Is there a better way to do it than that? This is a zr6 390 engine on a 2008 230 if that helps.

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[Paxdad]

I can tell you from experience that exhaust hose is not easy to manipulate. It would be easier to remove the exhaust riser which is the part above the manifold you are asking about. There is a gasket between the riser and manifold that will need to be purchased and replaced. Good luck and pray the nuts and bolts break free cleanly.


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[perry386]

Thanks Paxdad

Looks like I've got a lot of work ahead of me. Would you happen to know what torque the bolts would be. And is that something that I would want to do or take to shop


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[NautiqueJeff]

If I was doing that, I'd cut the old hose in half half way between the riser and the muffler. It'll be way easier to remove that way.

Once you have the old one off, lube up the connection points on the muffler and the riser with oil. That'll make the new hose go on easier.

You might try heating the new hose up if it isn't very flexible, and try to maneuver it into position without removing the riser.

[perry386]

Thanks Nautique Jeff
That's what I love about this for forum. I will try suggestion number two and if that doesn't work I'll go to Suggestion number one


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[DW SD]

Those are good tips. Those hoses ate inflexible and will out up a fight without the riser being removed.

I'm guessing since some exhaust gas will contain oil that the hose is impervious to oil.
It is good practice to lube rubber parts with silicon grease vs. petroleum based. The petroleum based will break down rubber over time.
I have a eight ounce tube of rubber compatible silicon grease that's lasted me for ten years. Got it at Napa.

On the boat it gets used on rubber impellers, O rings, etc.


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[Erikgundy98]

So does suggestion #2 work? Heat and lube. Im in the same boat... having to replace the InvertaFlo muffler. Figure I will try heat the tubes to get them off, but .... has anyone had heat work in getting the old tubes off? I seem to remember having to cut the last ones off a decade ago.... but cant remember.

Thanks

[bturner]

I've only done 2 and pretty much did as Jeff recommends. We used a Sawzall and cut 3/4 through the hose in 1 location then moved up the hose about 3" and completely cut through on the top location. This let me fold over the section of the hose to cut that section out and gave me room to pry, twist and yank on it. You can also score the hose with a razor knife where it connects to the riser which will help break it free. A heat gun does help as well. As to removing the risers.... It's a great idea in theory but I personally hate messing with them and would rather spend 2 hours fighting with the hoses than screw with those bolts and have on possibly break off but that's me. Not a fun job to say the least.

Heat will help with reinstallation but those hoses are stiff even when warm. It's been years but I recall setting the hoses out in the sun to heat them up and I believe we used silicone spray on the ends. Using some kind of lube will definitely help. Be careful if you use a heat gun for the installation as you don't want to get it too hot and compromise the hose.

[Stevemo14]

I replaced my fuller in my 05 SANTE last summer. I ordered new Hoses from Nautique Parts, 5 LNFT, and the new muffler.

From there, I actually got the old muffler out without removing the hoses from the manifold. I removed them after anyways due to replacement. I ended up just making a cut down the hose to release it from the manifold. used some steel wool to clean it up, and the new ones slid right on.


Th most difficult part was getting the bottom outlet hooked up. I installed the hoses from the risers first, then had to fenagle the muffler into the bottom exit hose.

[SilentSeven]

Lots of correct words here.

...use a Sawzall ....
...pry, twist and yank...
...a heat gun helps...
...those hoses are stiff...
...silicone spray on the ends...