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Renewing the Exhaust System on a Series Land Rover

Ground clearance is usually sufficient on a Series Land Rover to be able to renew an exhaust system without the need to jack up the vehicle. If you do use a jack though be sure to support the raised section on axle stands. Do not work on a hot exhaust and wear eye goggles because rust flakes very easily drop into the eyes. Before you start work check that all the brackets and rubber mounting strips are re-useable or order replacements first. Simlarly check that you have new gaskets, jointing compound and replacement bolts for any that will not be re-used.

The front section of the exhaust tends to last longer than the later sections due to it operating at a higher temperature and being able to evaporate condensed water more easily as the system cools down. If you are not planning to renew the front section then it is still a good idea to remove and replace the exhaust manifold nuts individually (so as not to disturb the pipe to manifold seal). By doing this you are reducing the chances of these nuts seizing up and becoming a problem in the future.

A good starting point is to soak nuts and bolts with penetrating oil well before attempting to loosen them. This is particularly important for the exhaust manifold fixing nuts. You will change a short job into a major repair if you break a manifold stud by applying too much torque to the nut(see photo). It is good practise to coat these threads with a high temperature copper-based grease when re-assembling. You may just as well saw though the bolts connecting the downpipe to the rest of the system and fit new ones on re-assembly as they will probably cause you more hassle to try to unfasten them. They are most exposed to wheel spray and corrode badly.

 

Finally, before removing the system, check on the flexibility and routing of the pipes. Does anything need altering when you fit the new system? Has corrosion been encouraged by too much stress at some point?
Refit the replacement pipes using exhaust jointing compound or gaskets where appropriate but do not fully tighten any bolts until you are sure the system is correctly hung and will not be stressed by lack of flexibilty in the mountings. Then quickly tighten the bolts starting with those joints that are sealed with compound as you only have a few minutes before it hardens.

Mild steel exhaust systems only have a life of a few years in a damp climate so if you have access to a stainless steel option, and the finances to pay for it, then you may not need to renew your exhaust system again. However, the mountings will remain mild steel and so will still require periodic inspection and replacement if necessary.

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Fascinating facts
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Series II's for the Canadian market had one-piece cab doors.

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