Gearbox reseal time?

[notorious]

Adrian, what is the condition of your Milltek exhaust? I mean if you put car in the air and look at pipework?

This is what I've read on Milltek web site in Pedigrees section: "Milltek Sport exhausts are produced in high quality type-304 aircraft grade stainless steel."

304 is lowest grade stainless steel, which will not even remain polished and shiny if exposed to street conditions. This lowest grade steel will discolorate simply if I leave a piece of pipe outside my house for a couple of months. Forget about exhausts. Exhaust pipes made of 304 stainless steel will be completely rusty within half a year for sure. Why don't they use at least 316 grade stainless steel is beyond me if they position their stuff as premium product. I wonder if there are proper exhausts on the market that will actually stay shiny for lifetime of car.

[brasiliangringo]

My experience is they give the impression of a severe loss when in fact plenty of fluid still exists inside. What your pic shows in a leaking flange seal on the transfer box / output shaft. It has its own filling blue plug at the top which may be accessible at a squeeze without lowering the subframe and gearbox but on 2nds thoughts probably not.

[notorious]

Thanks gringo,

This is exhaust out and propshaft out job well documented on audipages.com. I already purchased new seal and new flange and all bolts from Audi. Some hardware for exhaust too.

I'm only worried that my exhaust is relatively rusty and if disturbed it may be impossible to put it back together again, so I'm studying 'plan b' options for third party exhaust, but it seems Audi stock ones are the best even the price tag is very expensive.

[brasiliangringo]

Ive just done some work on my S8 which involved removing the front right pipe to change the flange seal on the final drive amongst other things, and i just cut the exhaust clamp off with a grinder as bolts too far gone, then replaced with a new sleeve clamp. No problems re disturbing the original exhaust etc. Car is on 160k, 2002.

[notorious]

Originally Posted by brasiliangringo

Ive just done some work on my S8 which involved removing the front right pipe to change the flange seal on the final drive amongst other things, and i just cut the exhaust clamp off with a grinder as bolts too far gone, then replaced with a new sleeve clamp. No problems re disturbing the original exhaust etc. Car is on 160k, 2002.

Yep, I already purchased two clamp sleeves and they come with bolts. I'm more worried about flanges towards front of the car. Those with metal gaskets in between. Bolts are gone on them and flanges themselves are not very healthy too. I'm worried about those flanges. Obviously, all old bolts are to be cut. We'll see.

I've got 2002 with 83000 miles.

[ainarssems]

I did my last summer. Replaced seal with with audi part but left the old flange. Also replaced propshaft front CV joint as the boot had failed, grease gone out and it's bee running dry for a while and broke when I was pulling it off to replace boot. I only removed cats and left rest of exhaust and propshaft in place.

[Adrian E]

The exhaust looks good underneath - I don't have a recent pic but can get one if you want.

Had a bad day with the car so don't particularly want to go near it tonight