Smart 451 Exhaust Leak DIY Repair

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This video looks at doing a DIY repair of a leaking flex pipe on a Smart ForTwo 451. This is a very common failure on these cars and an OEM replacement muffler is easily $500-600 just for the part. It's much more economical to just cut out and weld in a new flex pipe. I've got the rear bodywork removed on the car because I was working on other things, but it is possible to do all this work without removing the rear panels.
Flex pipe diameter : 1.75"
The pipe diameter is slightly different on the smart so you might have to get creative. In my case the pipe had already been replaced so I used the previous replacement pipe as a step-up in pipe diameter.
Smart Tech Series Playlist: • Smart ForTwo Tech Series
Instagram: @pbgaragelive
Facebook: / pbgaragelive
0:00 Look at issue
0:20 Mark Cuts
1:24 Remove Muffler
1:59 Repair Heat Shield
4:55 Prepare To Install New Flex
6:04 Tack Weld
6:38 Reinstall Repaired Muffler
7:00 Check For Leaks
7:32 Listen To Sporty Revs

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Опубликовано:

3 авг 2024

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Комментарии : 36

@rockcrusher4636 3 года назад

Nothing to swear about that's how we get that super valuable experience. Great vid, thank you. Cheers.

@PBGarage 3 года назад

Exactly!

@RAYMONDBernardin-xo2ed 10 месяцев назад

I took mine out, cleaned up the contacts and bam! Works like a charm

@PBGarage 10 месяцев назад

Do you mean the alternator?

@simsneon2 3 года назад

Thank you I appreciate you’re smart videos

@PBGarage 3 года назад

Thanks! They’re great cars but often cost too much to have repaired for what they’re worth so if I can help people keep them on the road affordably I’m happy!

@door2416 2 года назад

Great timing to find this video. Just found out my 2015 Brabus has the same issue. I don't weld so will be using clamps.

@PBGarage 2 года назад

That’s going to be really tough as the pipes are slightly different sizes top and bottom.

@door2416 2 года назад

@@PBGarage Good to know. Guess i'll be calling in some favors from my friend who welds. Thanks

@PBGarage 2 года назад

It’s worth the extra effort just to not have to try and mess around with the clamps being in the way, it’s pretty tight under the car where the flex pipe is.

@bquattrog 3 года назад

I’m concerned the M8 heat shield bolts will not be strong enough because of the muffler heat and bouncing loads. Defo should have gone M12+ IMO. 🤣 Nice execution and I like the use of the jack for the reference point 👍🏻

@PBGarage 3 года назад

I was looking for some M16 Inconel bolts but it’s been a while since I’ve gone scrap diving at the submarine harbour.

@rocknut144 3 месяца назад

Lol the one part i needed was skipped. Im having soo much issue putting the back bolt in.

@PBGarage 3 месяца назад

The two bolts on the flange you mean?

@rocknut144 3 месяца назад

@PBGarage yes sorry. I managed to jerry rig a flexible joint to attach to my tork and hated every second of getting it to catch. Still your video and ones like it are a service thank you

@PBGarage 3 месяца назад

@rocknut144 thanks! Yeah the bolts are hard to get to and corrode very easily so I always end up punching the captive nuts off the back side with an air chisel, then I install new bolts+nuts when I reinstall, so the next time I’m doing the job they are easy to get out again.

@zetron1234 9 месяцев назад

I just found out my 2010 Brabus has the same issue. I guess that's what I'm tackling this weekend. I see you used 1.75" which is fine, but how long? I see 8 and 10". I feel I can just cut down the 10", but someone mentioned that the 10" is too long. And the material is SS so when you welded, did you weld SS or just normal MIG? I weld normal steel, but no TIG Capabilities as of yet but do you think the normal steel welding will hold up long enough or should I get it welded up SS? Great video by the way. Thanks

@PBGarage 9 месяцев назад

Thanks! If 8” includes the ends which you’ll be cutting and bending I think you’ll be ok. If the flexy part itself is 8” you may not have room to fit it in. I think the shorter the better as long as you have enough pipe to make up the difference.

@PBGarage 9 месяцев назад

Also, I used just mild steel to weld many many of these up. The welds always far outlast the replacement flex pipes, so I’ve never been worried about it. I’ve been using flux-core wire with a MIG, except no gas just the flux core in the wire.

@mikey2811 3 года назад

I've read that the flexi pipe is either 1 5/8" or 1 3/4" pipe, about 8" long. Any idea which is correct?

@PBGarage 3 года назад

I've been using 1.75" pipe, which a little bit larger than OEM, but it gets tricky because the inlet and oulets aren't the same size with the bends in the factory pipe. I got a pipe that was a bit shorter than 8" so that I had a bit more room to get creative with placement. It's easier to cut some slots in the larger pipe and hammer them in and weld up the slits, than it is to try and expand a 1.525" pipe.

@maxzamos8966 Год назад

I notice that you never show the removal or replacement of the flange bolt furthest from you. Could that be because that one is a real nightmare to get to? lol And that's also why I'm surprised you choose to refit the heat shield before re-attaching the manifold. It's much easier to do with the heat shield off.

@PBGarage Год назад

I never touched the manifold, and both bolts at the flange for the muffler are a real pain, and mine were so rusted the bolts snapped on removal, and I punched the “captive” nuts out with a hammer, opting to replace with hex head bolts and normal nuts for ease of future removal. I thought I covered all that in the video but that was quite a long time ago.

@LSmiata 10 месяцев назад

Did you lower the subframe to get more access? I am in the process of replacing exhaust and have no room to body structure. No room and even though this car has very little winter time, the heat shield bolts on the cat have lost mass and forced me to order E-Torx end wrenches. Will not arrive for two days......grrrrr. Please advise. P

@PBGarage 10 месяцев назад

No I didn’t lower the subframe to work on the exhaust. But removing the lower half of the rear bumper, crash bar, and the X brace at the back of the car can make your life a lot easier.

@petersimms4982 2 года назад

Hi what size is the repalacement flexi pipe?

@PBGarage 2 года назад

I’ve been using 1-7/8” x 4”, it’s a bit bigger than stock but allows me to cut and fold the ends a bit to account for the curved pipe etc

@sullaimaanfazil1420 2 года назад

Was this car smoking a lot before? I have a 2009 smart fortwo and been told I’m in need of a new exhaust system ($1200)

@PBGarage 2 года назад

No the car never smoked.

@sullaimaanfazil1420 2 года назад

Would a broken/ cracked flexi pipe cause smoke? White smoke

@pappydanny58 3 года назад

Replace that flex pipe once. Lasted for a year and the same thing happened

@PBGarage 3 года назад

There are definitely better and worse quality of flex pipes to use. I’ve had a similar experience with a cheap one that only lasted a year or two as well.

@pappydanny58 3 года назад

@@PBGarage Ridgid pipe probably last forever