2005-2008 Hyundai Tucson Exhaust Leak Repair | V6 FWD

Summary

In this garage workshop video, the host tackles an exhaust leak on his wife's 2006 Hyundai Tucson. Initially, he mistakenly orders the wrong exhaust part for the front-wheel drive model but ingeniously adapts it by cutting and welding. With the help of a newly acquired MIG welder, he replaces the faulty flex joints, ensuring a tight seal with high-temperature gasket maker. After a meticulous installation and letting the RTV gasket maker cure overnight, the repair is tested with a successful first startup, demonstrating a practical DIY solution for a common car issue.

Takeaways

• 🔧 The video is about fixing an exhaust leak on a 2006 Hyundai Tucson V6, which is the 'beater car' of the narrator's wife.
• 🛠️ The narrator ordered the wrong exhaust part, mistaking it for the correct one due to a misunderstanding of the differences between front-wheel and all-wheel drive models.
• 🔄 The main difference between the two exhaust parts is the angle of the bend near the exhaust manifold, with a 90° bend for front-wheel drive and a 45° bend for all-wheel drive.
• 👷‍♂️ The narrator plans to rectify the mistake by cutting and welding the 90° bend from the old exhaust onto the new one.
• 🚧 The narrator purchased a new MIG welder, the Prime Weld Mig 180, to perform the repair, which was a long-considered purchase.
• 🔩 The repair involves removing six bolts at three connection points, which are likely rusted and will require careful handling.
• 🔍 Upon removing the old exhaust, it was discovered that the leak was coming from a failing front flex joint that fell apart.
• 🧩 The narrator noticed that the hardware kit for the new exhaust might be missing some parts, specifically larger nuts for the rear connection.
• 🛠️ The repair process includes cleaning up rusted threads with a tap and die set and ensuring the correct size nuts are used for a secure fit.
• 🔨 The narrator uses a chisel and hammer to remove old gasket material and plans to use high-temperature exhaust gasket maker for a better seal.
• 🔧 After welding the old 90° bend onto the new exhaust, the narrator applies high-temperature RTV gasket maker to ensure no leaks post-installation.
• 🚗 The final step includes bolting the new exhaust system in place, allowing the RTV to cure overnight, and testing for leaks with a startup the next day.

Q & A

What is the main issue the narrator is addressing in the video?

The main issue is an exhaust leak in the narrator's wife's 2006 Hyundai Tucson front-wheel drive car.

Why is the car referred to as a 'beater car'?

The car is called a 'beater car' because it is being used as a temporary vehicle while the wife's other car is broken down.

What mistake did the narrator make when ordering the exhaust part?

The narrator ordered the wrong exhaust part, not realizing there is a difference between the exhaust systems for front-wheel drive and all-wheel drive Tucson models.

What is the difference between the exhaust parts for front-wheel drive and all-wheel drive Tucson models?

The difference is in the angle of the bend where the exhaust connects to the exhaust manifold; it's a 90° bend for front-wheel drive and a 45° bend for all-wheel drive.

What tool did the narrator purchase to fix the exhaust issue?

The narrator purchased a Prime weld MIG 180 welder to cut and weld the exhaust parts.

How did the narrator ensure the car was stable while working on it?

The narrator used two 6-ton jack stands under the frame rail and a jack under the frame as a backup safety measure.

What was the source of the exhaust leak identified by the narrator?

The exhaust leak was coming from the front flex joint and possibly other pinholes in the exhaust system.

What additional items did the narrator need to purchase for the repair?

The narrator needed to purchase M12 by 1.5 nuts, gasket maker, and a new grinder disc.

How did the narrator plan to correct the mistake of ordering the wrong exhaust part?

The narrator planned to cut the 90° bend from the old exhaust and weld it onto the new exhaust part to make it fit correctly.

What safety measure did the narrator take before fully installing the exhaust system?

The narrator planned to apply high-temperature exhaust gasket maker on both sides of the gaskets to ensure a good seal and prevent leaks.

What was the final step before starting the car after the repair?

The final step was to let the high-temperature RTV gasket maker cure overnight before starting the car to check for leaks.

Outlines

00:00

🔧 Repairing a Hyundai Tucson's Exhaust Leak

The video begins with the host introducing a repair task on his wife's 2006 Hyundai Tucson, which has developed an exhaust leak. The car, referred to as a 'beater' due to its current condition, has a front-wheel drive setup. The host explains that he mistakenly ordered the wrong exhaust part, as the front-wheel drive model has a 90° bend different from the all-wheel drive model's 45° bend. Despite the error, he plans to modify the new part by cutting and welding the correct bend from the old exhaust. The host also shares his recent purchase of a Prime Weld Mig 180 welder and his process of safely jacking up the car for the repair. The video captures the initial steps of removing the faulty exhaust system and identifying the source of the leak.

05:01

🛠 Addressing the Exhaust Part Error and Hardware Issues

In this segment, the host continues his repair work by addressing the mistake in the ordered exhaust part. He details the process of test-fitting the new exhaust and planning how to integrate the correct 90° bend from the old exhaust system. The host also encounters a problem with the hardware provided with the exhaust kit, realizing that it is missing some necessary components. He decides to clean the threads on the existing studs and purchase the correct size nuts. Additionally, he removes the old gasket and plans to apply high-temperature exhaust gasket maker for a better seal. The host demonstrates the dry fit of the new exhaust, identifying where he needs to cut and weld the old piece onto the new one to correct the error.

10:02

🔨 Completing the Exhaust Repair and First Start

The final paragraph of the script describes the host's completion of the exhaust repair. He successfully cuts and welds the old elbow onto the new exhaust, ensuring a proper fit and seal. The host also applies high-temperature RTV gasket maker to the gaskets to prevent any leaks. After bolting the new exhaust system in place, he plans to let the RTV cure overnight before starting the vehicle. The video concludes with the first startup after the repair, indicating a successful fix if there are no leaks. The host thanks viewers for watching and hopes the video helps those facing a similar issue with their Hyundai Tucson.

Keywords

💡Beater Car

A 'beater car' is a colloquial term for a vehicle that is old, worn out, or in poor condition, often used as a backup or secondary car. In the video, the term is used to describe the wife's car which is now the primary vehicle due to the breakdown of her other car. The beater car in this case is a 2006 Hyundai Tucson with a front-wheel drive.

💡Head Gasket Job

A 'head gasket job' refers to the process of replacing the head gasket in an engine, which is a crucial seal between the engine block and the cylinder head. The script mentions that the car's owner was working on this repair, indicating a significant mechanical issue that the car was facing.

💡Exhaust Leak

An 'exhaust leak' occurs when there is a breach in the exhaust system, allowing exhaust gases to escape before they are fully expelled through the tailpipe. This can lead to decreased performance and potential environmental hazards. The video's main focus is on fixing an exhaust leak in the Hyundai Tucson.

💡Front-Wheel Drive

Front-wheel drive (FWD) is a vehicle configuration where the engine drives the front wheels only. This is contrasted with all-wheel drive (AWD) where power is distributed to all four wheels. The script discusses the difference in exhaust parts for FWD and AWD models of the Tucson.

💡Exhaust Manifold

The 'exhaust manifold' is a part of the exhaust system that collects exhaust gases from the engine's cylinders and directs them to the exhaust pipe. The script mentions a difference in the exhaust manifold connection for FWD versus AWD models, which led to the ordering of the wrong part.

💡MIG Welder

A MIG (Metal Inert Gas) welder is a type of welding machine that uses a continuous solid wire electrode fed through a welding gun to join metal pieces. The script describes the purchase of a Prime Weld MIG 180, which the owner uses to correct the exhaust part mistake.

💡Jack Stands

Jack stands are safety devices used to support a vehicle when it is lifted off the ground, ensuring that the vehicle remains stable while work is being performed underneath. The script mentions using two 6-ton jack stands for safety while working on the car.

💡Flex Joint

A 'flex joint' is a component in the exhaust system designed to absorb vibrations and allow for some movement in the system without damage. The script identifies a leaking flex joint as part of the exhaust leak issue.

💡Gasket Maker

Gasket maker is a sealant used to create a tight seal between two surfaces, often used in automotive applications to prevent leaks. The script describes using high-temperature exhaust gasket maker to ensure a good seal on the new exhaust system.

💡RTV Silicone

RTV (Room Temperature Vulcanizing) silicone is a type of sealant that cures at room temperature and is commonly used in automotive applications for its durability and resistance to high temperatures. The script mentions using high-temp RTV gasket maker to seal the exhaust system.

💡Bolts and Nuts

Bolts and nuts are fasteners used to hold parts together. In the context of the script, they are essential for securing the exhaust system to the car. The owner discovers that the new exhaust kit may be missing some necessary hardware.

💡Dry Fit

A 'dry fit' is the process of assembling parts together without using any fasteners to see if they fit correctly. The script describes using a dry fit to determine how to modify the new exhaust part to fit the car correctly.

Highlights

Introduction to the repair of the wife's beater car, a 2006 Hyundai Tucson with a front-wheel drive.

Mistake in ordering the wrong exhaust part due to a difference between front-wheel and all-wheel drive models.

Description of the difference in exhaust design between front-wheel and all-wheel drive Tucson models.

Purchase of a new welder, the Prime weld Mig 180, to address the exhaust repair.

Safety measures taken while jacking up the car for repair work.

Identification of the source of the exhaust leak from the front flex joint.

Decision to cut and weld the 90-degree bend from the old exhaust onto the new one.

Realization of missing hardware in the exhaust kit and plan to clean and match the correct nuts.

Use of a chisel and hammer to remove the old gasket and rust.

Application of high-temperature exhaust gasket maker for a better seal.

Dry fit of the new exhaust to determine the cutting and welding points.

Tacking the old elbow to the new exhaust and planning to fill the gap for a proper seal.

Welding the new elbow to the old exhaust piece and sealing the connection.

Installation of the repaired exhaust system with high-temperature RTV gasket maker.

Plan to let the RTV cure overnight before testing the repair.

First startup after the exhaust leak repair and confirmation of a successful fix.

Conclusion and thanks for watching, offering help for those fixing a Hyundai Tucson exhaust leak.

Transcripts

[Music]

all right what's going on guys welcome

back to the oven's garage today I'm

going to be working on my wife's beater

car yeah that's right you heard me right

I said beater car because her other car

is broken down right now and I'm doing

the head gasket job but her beater car

sprung in an exhaust leak and it's a 200

six I think Hyundai Tucson front-wheel

drive and it's got a bad exhaust leak

that just started developing the past

couple weeks and it's starting to annoy

me and all the neighbors so I ordered an

exhaust part and we'll get that exhaust

part changed out although when the

exhaust part showed up I realized I made

a mistake in the part that I ordered and

I didn't I didn't realize that there's a

difference between the between the

exhaust on the Tucson for the front with

drive versus the all-wheel drive here's

the exhaust here that I

ordered and the only difference between

those two parts is right here so I saw

this little Bend and I you know thought

it was the right part but there's a

difference between here and where it uh

bolts up to the exhaust manifold so on

the front wheeel drive models this is a

90° it comes right up and uh on the on

the all-wheel drive models it's this is

the all-wheel drive model it kind of

just goes up to like a 45 so I ordered

the wrong exhaust part but the rest is

exactly the same so what I'm going to do

is I'm going to take uh the old exhaust

off and I'll just cut and

weld um the 90 from the old one onto

this one I've been meaning to buy a

welder for a long time and I finally

pulled the trigger so I got this Prime

weld Mig 180 it's a dual voltage got

some shielding gas are gone with it and

uh came with everything I needed pretty

much so uh I bought a welder yay finally

so now I'll go ahead and rip the exhaust

off her car it's a hot day today in the

garage right now it's 22 4 6° and

outside right now it's like

29 there's the

Hyundai it's at

2006 so I'll get it jacked up put on

jack stands and I'll start ripping the

exhaust off okay so I've got the car

safely jacked up I'm using two 6 ton

jack stands under the frame rail so

these are the frame rails here on each

side I'm as close as I can get to the

front um so that way the Pivot Point all

the weight of the engine will not uh

bring up the back end of the car so this

is pretty stable and then I have a jack

uh under there as well just with a

little bit of tension on the frame as a

backup safety measure so if you didn't

order the wrong part this is actually

quite a straightforward swap there's six

bolts because there's three connection

points um they're likely going to be

rusted out two bolts

here or sorry two bolts

here two volts here you can see that's

the 90 I was talking about and then two

volts up at the front so once you get

those off um it's really just a

straightforward Swap and the kick comes

with new hardware anyways so the exhaust

leak is coming from up there you can see

that front Flex joint and this is the

other Flex joint I think it's leaking a

little bit as well

it's time I know that I'm not easy this

cold of mine she really took a Bea

before

you you stuck through Pleasers winter

nights with

[Music]

you all right so here's a quick look at

the old exhaust and the new exhaust you

can see where I ordered the wrong part

here um front-wheel drive has the 90° it

goes up and the all-wheel drive has like

the 45 otherwise the exhaust is pretty

much exactly the same when I was taking

the exhaust off at the front this Flex

joint when I unbolted those two this

just fell apart in two pieces so our

exhaust Sak was coming from there and a

couple different places around here

there's a couple pin holes in the flex

joint I imagine there's a couple under

here too but what I'm going to do now is

I'm going to take the new

exhaust uh I'm going to dry fish fit it

and kind of see exactly where I need to

uh cut this off the old exhaust and then

weld it onto there all right so I was

just test fitting the hardware that came

with the kit and I realized I don't

think it comes with everything it's got

three gaskets um two bolts Two Nuts and

two washers but the problem is I think

uh maybe it's different on the other kit

but the two bolts are the front uh the

two nuts go up to the other side of the

engine block uh after that kind of

curved part of the ex and then there's

there should be two more nuts for the

back that are a little bit bigger than

these ones so these two are for the

front I just tried threading them on by

hand uh what I'm going to do is clean up

the threads with a top and a die

3816 and then I got to find the right

size uh nuts to go on the existing uh

stud that's uh to the to the rear of the

car um and I'll clean up those threads

as well with a die just ensure the

smooth uh kind of the nut goes on

smoothly on those two studs

for

[Music]

there's there's nothing I wouldn't do

for

you there's nothing I

wouldn't for

you

there's

for okay now that I've used the D on

these threads that'll thread on okay on

both sides and then this bolt will

thread okay into these

threads I tap these back holes to M12 by

1.5 so I'm going to go and get two M12

by 1.5 nuts for that I've also gone and

taken a chisel and a hammer and got off

some of the remaining uh

gasket cuz the old gasket was kind of

stuck on the surface with some of the

rust there uh what I'm also going to do

before I fully install the system is I'm

going to get some gasket maker high temp

exhaust gasket gasket maker from

Canadian Tire and I'll put that on both

sides of the gaskets that come with the

kit just to ensure a good seal uh once

I've tightened everything

up um at this point I'm going to dry fit

the exhaust and see what I need to do in

order to correct my mistake by ordering

the wrong

exhaust uh cutting and

buing a little bit of the old system

into the new system here all right so

I've got the exhaust uh dry fitted up

here and because of the flex joints it

actually fits quite nicely I've just got

it hanging with a bolt up on this end

and as you can see the 45 doesn't quite

make it here so I've cut off the 90 from

the old

piece and if I kind of hold it roughly

same length away uh it's going to work

out I've hold it hold it both ways kind

of this way and that way and I can see

that it'll line up so I just need to had

to trim this back a little bit and then

I'll probably end up cutting this maybe

around here um and then just weld it at

that seam so I need to run to the store

to grab a couple things those nuts the

gasket maker and another grinder disc

and we'll get to get to welding all

right so I've got the new piece

cut and kind of made it into the old

piece uh I've got a gap here that's a

little bit bigger than I wanted it to be

but uh what I'm going to do is I'm going

to T it in a couple spots and then I'll

take the whole thing out and then fill

in that Gap I'll make a nice a nice seal

around there and then we'll be good so

I'm going to tack a couple spots with

the welder and then take it out and weld

it all around all right so I've tacked

it in three spots and now what I'm going

to do is take this system off get it

into an easier spot to weld and then

weld it completely around solid okay so

I've welded the uh new elbow or sorry

the old elbow to the new

exhaust got it all welded and sealed up

and at this point I can throw it in the

car um I got

some high temp

RTV uh gasket maker and I'll throw that

on each side of the the gaskets that

came with the exhaust just to make sure

there's uh no leaks and we'll get it all

bolted in uh right now

[Music]

[Music]

[Music]

all right so the new exhaust is all

bolted up got everything tightened

down I just made it uh all pretty tight

uh without stripping the bolts or nots

obviously we got the new system fully

installed so I'm going to let that RTV

cure overnight and then we'll drive it

tomorrow um and I guess we can consider

this done as long as there's no leaks

I just got to fix this Splash shield and

I'll take everything off the jack stands

and uh let it sit overnight before we

start it up and close out this video

okay this is the first startup after the

exhaust leak repair

[Music]

all right thanks for watching hopefully

that helps you if you're trying to fix

an exhaust leak on your Hyundai Tucson

this is a 2006 V6 cheers

[Music]