Exhaust Flex Joint - Chirp/Clunk Noise

88chrysler04

Models


1987 and 1988 C-E-G-H-J-K-L-P- & S-Body Vehicles With 2.2L and 2.5L Engines


Subject

Exhaust Seal Ring Service To Correct Chirp, Clunk, and/or Leak


Index

EXHAUST


Date

April 25, 1988


No.

11-01-88

P-1554 (C11-01)
SYMPTOM/CONDITION

^ Exhaust flex joint (seal ring) "Chirp" or "Clunk," which is most noticeable when shifting from neutral to drive or reverse.

^ Momentary exhaust leak during engine rotation under acceleration.

NOTE: VEHICLES THAT HAVE AN EXHAUST SQUEAK ON ACCELERATION WILL NOT BE IMPROVED BY PIPE SIZING.

DIAGNOSIS

Road test vehicle to verify that noise/leak is coming from the exhaust seal ring.

PARTS REQUIRED

Order the following parts for the vehicle being repaired:

2 Shoulder Bolts PN 5217003
2 Nuts PN 6100499
2 Springs PN 4301631

REPAIR PROCEDURE

NOTE: ALL 1988 2.2L AND 2.5L NON-TURBO VEHICLES BUILT AFTER 11/01/87, HAVE HAD THIS PIPE SIZING PROCEDURE DONE IN ASSEMBLY AND SHOULD NOT REQUIRE SERVICE IN THE FIELD.

ONCE THE SEAL RING IS SIZED TO THE PIPE IT CANNOT BE REPLACED.

1. Remove clamp at the first slip joint and carefully separate exhaust system at that point.
NOTE: USE EXTREME CARE TO AVOID EXHAUST PIPE DAMAGE. IF THE EXHAUST PIPE IS DAMAGED DURING REMOVAL, REPLACEMENT WILL BE REQUIRED.

2. Remove the two shoulder bolts holding exhaust flex joint to manifold.

3. Inspect exhaust manifold seal area for burrs, nicks, and other imperfections in the mating surface of the manifold. Clean any imperfections with a wire brush or emery paper.

4. If needed, install a new seal ring on the pipe.

NOTE: THE FOLLOWING OPERATION REQUIRES THE USE OF A MULTI-SEGMENT HEAD HYDRAULIC PIPE EXPANDER. THE USE OF ANY OTHER TYPE OF EXPANDER MAY NOT UNIFORMLY EXPAND THE PIPE TO FIT THE SEAL RING.

5. With the seal ring positioned against the flange on the exhaust pipe, expand (size) the pipe carefully until the seal ring will no longer rotate on the pipe. Expand only the first 10 mm of the pipe on non-turbo engines and the first 15 mm on turbo engines.

CAUTION: DO NOT DAMAGE THE SEAL RING BY OVER EXPANDING THE PIPE.

6. Reinstall the exhaust pipe on the vehicle using new springs, shoulder bolts, and nuts. Torque to 250 in.lbs.

NOTE: DO NOT INSTALL ANY SHIMS UNDER THE SPRINGS OR OVER - TORQUE THE BOLTS.


POLICY: Reimbursable within the provisions of the warranty


TIME ALLOWANCE:
Labor Operation No. 11-20-01-90 . . . . . . . . . . 1.0 Hrs.


FAILURE CODE: 65 - Leaks