[axenstar]

Hi all,

2003, 1.8t, AWM, Bone Stock

I had a mechanic shop fixed the exhaust on my car. They simply welded a pipe on the part of the exhaust system that I showed in red in the picture. That section of the exhaust had rusted out, fell and the previous owner didn't fix it.

The clamp numbered 265-119 is not there.

The car vibrates annoyingly especially at high speeds.

I believe it is because of the exhaust.

[The motor (Corteco), transmission mounts (Corteco), shocks (Sachs), CV Axles (Raxles) all replaced.]

What can I do to the exhaust to get rid of vibration?

Thanks a lot.

 

[jjpark]

I would bring it back and have them check the rubber hangers (making sure they are all reconnected properly) and to make sure the exhaust is not up against any part of the car.

 

[VAGguy]

What they should have done was replace the parts with OEM equivalent or at least put it back together the same way. If they welded in a solid pipe, there was no room for adjustment to take undue pressure off the rest of the exhaust they connected to. Really, from the flex pipe to the suitcase muffler is all one piece now?

 

[cchief22]

something is tweaked, if they redo have them put in a new flex section as it will/would be next to go.

 

[axenstar]

What they should have done was replace the parts with OEM equivalent or at least put it back together the same way. If they welded in a solid pipe, there was no room for adjustment to take undue pressure off the rest of the exhaust they connected to. Really, from the flex pipe to the suitcase muffler is all one piece now?

Yes. It is one solid pipe from the bellow to the suitcase muffler. I did not know much about exhaust system when I got this car. So, I didn't question it. but as the vibration persisted, i did some research and exhaust system came to the fore as a culprit.

I have an OEM clamp shown in the diagram as 265-119.

Is it possible to cut the pipe at that location and use the clamp to release the stress?

 

[cchief22]

that is not a bad idea and will answer the question if indeed that is/was the problem, another possibilty is the motor mounts are toast which would precipitate early exhaust flex pipe area failure anyway, and 2003 probably has some miles on her ,curious though as to rust down there in Dixie.......near the ocean??? Will try and post pics on a solution I did with intentions of keeping my car in the rust belt even though not driving it in the winter, or at least at a minimum.

 

[axenstar]

This car lived most of its life in Rochester, NY. It’s been in the south for the last 3 years. That part of exhaus literally fell off on the driveway floor. Previous owner gave this car virtually for free. Because it wouldn’t pass Atlanta emission.

I replaced the motor and transmission mounts with corteco.

So, I think I m going to cut it in half and clamp it. Hopefully it will solve the vibration.

 

[VAGguy]

IIRC, the emissions is an ATL metro thing, right? We didn't have anything when I lived in Bartow county....

But yes, cutting it should relieve that stress

 

[axenstar]

IIRC, the emissions is an ATL metro thing, right? We didn't have anything when I lived in Bartow county....

But yes, cutting it should relieve that stress

Hi Vag,

Yes. It’s an Atlanta thing. I have heard people sell their cars cheap because it’s more expensive to fix in order to pass emission. Passat’s resale value was low anyways. So I got this one for $200.
Had 110.000 miles. Bullet proof engine.(compression was 180 on all cylinders) No rattling etc. but it had a mild rust problem, which I have improved to some extent. (Replaced the calipers etc.)

I am buying a reciprocal saw today. ?

 

[cchief22]

before you cut, run a magic marker front to back( longitudanal) so when you cut you can see if any stresses that were in it are now relaxed/relieved and I would also cut about a 1/2" section out. The clamp will easily cover that.

 

[jeffrycalhoun]

Are dual cat converters and heat shields still there? If removed or massacred, you will have problems. I used Borla replacements- not cheap, but less than half what vw parts cost. Original crossover pipe is flexible and extremely expensive. I had an exhaust guru weld in a solid pipe for cheap. Original systems don’t last for 80k and a dub dealer wants $4,000 to do it. Make friends with 3rd party suppliers, speed shops and mechanics and never visit the dealer.

 

[jjpark]

something is tweaked, if they redo have them put in a new flex section as it will/would be next to go.

Or already has lol

 

[jjpark]

Not sure why you would do the work yourself when you should be taking it back to the place that did the work incorrectly and have them fix it the correct way.

 

[axenstar]

Jeffry; I dont think my 1.8t has a dual exhaust. Am I right?

JJpark; the work was done in Charleston, SC and I am in Atlanta. 6 hour drive.
You are right. I would definitely take it to them.

 

[VAGguy]

Are dual cat converters and heat shields still there? If removed or massacred, you will have problems. I used Borla replacements- not cheap, but less than half what vw parts cost. Original crossover pipe is flexible and extremely expensive. I had an exhaust guru weld in a solid pipe for cheap. Original systems don’t last for 80k and a dub dealer wants $4,000 to do it. Make friends with 3rd party suppliers, speed shops and mechanics and never visit the dealer.

You're thinking of the V6. The 1.8T only has one cat (thank god!)

 

[axenstar]

Tomorrow I am planning to cut the pipe and bolt a clamp. Bentley says it reduces the stress.
On the original pipe there is a marking at the end of the first pipe where the clamp is supposed to be slid to. (Number 8 in the pic)
The pipe muffler shop welded is a plain pipe and doesn’t have marking.

Would it cause problem installing the clamp on a pipe without a marker?

 

[VAGguy]

It looks like it's there to have the proper spacing between the pipe ends so they do not touch in the middle. You should be ok without that. Just mark the pipe on both ends of the clamp and cut out a 1/4"-3/8" section in between for adjustability.

 

[axenstar]

Thank you VAG,
Do you know how the proper adjustment is done?