3.9L common exhaust problem
Errr!! This summer I disconnected the entire exhaust (since I was afraid to tackle the rusty bolts at the flange to the muffler) and found the source of that annoying exhaust leak. Apparently, the flange on the Y pipe (NAS driver's side) has a known history of cracking right at the base of the pipe to the flange, causing the wonderful puttering sound upon acceleration (and decreasing gas milage by about 3-4 miles per gallon). I was able to lower the exhaust assembly enough to get a bead of weld on the crack, but just the other day the sound began to re-appear. I admit my welding skills are ugly at best, but they seem to work. With the sound beginning to reappear, I went online to see what the cost of a new Y pipe would be (figuring that you can only band-aid something for so long). To my delight, I found the assembly was only $580 (meaning I would save myself $580 because there's no way I can see spending that much). SO.... anybody have any ideas? Can you buy just the flanges anywhere? Am I stuck with simply goobering-up my existing flanges with weld? 
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Drewfuss
'63 Series IIa: parabolic spring packs, 33x9.50 mud tires, Kodiak Heater, Fairey OD (SOLD)
'95 Jeep YJ: 8"lift (SOA), 35x12.50BFG Muds, Ford 8.8 rear w/detriot & disc brakes, 4.88 gears, warn8000i, daylighters......
'99 Jeep XJ: 3" Skyjacker, 31x10.50 MTR (SOLD)
'95 NAS D90 Wagon, front skid plate, brushguard, Hellas, 285/75 R16 Dunlop Mud Rovers, custom guages & dash
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