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Car Forum / Dodge / Dodge Trucks / December 2005

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stainless steel exhaust system

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J - 07 Dec 2005 22:40 GMT
Did the '02 Durango come with a stainless steel exhaust system?  I could've
sworn I saw that in the brochure and on the window sticker but I'm not so
sure that's what I got.  I had my D at my mechanic the other day to check
out a noise coming from the front wheel area (turns out a little lubrication
solved the problem) and I mentioned to the mechanic about my exhaust system.
He mentioned that if it truly was stainless, it shouldn't have been showing
signs of rust, as it was.  Anyone have any info on this?

P.S.  I just checked the catalog for the '02 Durango.  It says it comes with
a "full stainless steel exhaust system."  Maybe I don't have a full
understanding of "stainless," but I was under the assumption that it doesn't
rust.  My stainless steel kitchen knives don't rust so why should this?
.boB - 07 Dec 2005 23:06 GMT
> Did the '02 Durango come with a stainless steel exhaust system?  I could've
> sworn I saw that in the brochure and on the window sticker but I'm not so
[quoted text clipped - 8 lines]
> understanding of "stainless," but I was under the assumption that it doesn't
> rust.  My stainless steel kitchen knives don't rust so why should this?

     Yes, I believe it did come with a stainless exhaust.  However, there are
various grades of SS.  It will rust; just not nearly as fast as standard steel.

Signature

.boB
1997 HD FXDWG - Turbocharged   Stolen 11/26/05 in Denver
    1HD1GEL10VY3200010    CO License J5822Z
2001 Dodge Dakota QC 5.9/4x4/3.92
1966 Mustang Coupe - Daily Driver
1965 FFR Cobra -  427W EFI, Damn Fast.

Tom Lawrence - 08 Dec 2005 00:47 GMT
> rust.  My stainless steel kitchen knives don't rust so why should this?

Are your kitchen knives constantly exposed to heat, acids, and moisture on
one side, and water and road salt on the other?

Rust is the result of oxidation of iron.  Stainless steel, although
containing a fair amount of chromium and nickel, is still mostly iron.
J - 08 Dec 2005 00:55 GMT
So they don't make truly stainless steel exhaust systems that don't rust at
all?
>> rust.  My stainless steel kitchen knives don't rust so why should this?
>
[quoted text clipped - 3 lines]
> Rust is the result of oxidation of iron.  Stainless steel, although
> containing a fair amount of chromium and nickel, is still mostly iron.
Tom Lawrence - 08 Dec 2005 01:18 GMT
> So they don't make truly stainless steel exhaust systems that don't rust
> at all?

It's physically impossible to produce an alloy of steel that "never" rusts.
However - higher quality stainless steels will resist rusting better than
lower quality ones.  The goal of the automaker is to produce an exhaust
system that doesn't rot through for the life of the vehicle's warranty.
Given that the maximum lifetime of that warranty is 7 years or 100,000 miles
(biggest service contract you can buy), the fact that your 4-year-old
exhaust is starting to show signs of surface rust (and I'm sure that's all
it is), I'd say it's perfectly normal.
nospam.clare.nce@sny.der.on.ca - 08 Dec 2005 04:31 GMT
>> So they don't make truly stainless steel exhaust systems that don't rust
>> at all?
[quoted text clipped - 7 lines]
>exhaust is starting to show signs of surface rust (and I'm sure that's all
>it is), I'd say it's perfectly normal.

As has been stated, there are many kinds of stainless. They have
different qualities. Those that take a beautiful shine and are
virtually corrosion resistant don't take kindly to the heat and
vibration. Cracked exhaust systems are worse than rust stained exhaust
systems.
The biggest problem with factory stainless systems is the joints are
mig welded with what is basically a mild steel wire, so the welds rust
off.
Big Al - 08 Dec 2005 15:00 GMT
> > So they don't make truly stainless steel exhaust systems that don't rust
> > at all?
[quoted text clipped - 7 lines]
> exhaust is starting to show signs of surface rust (and I'm sure that's all
> it is), I'd say it's perfectly normal.

Any idea why Chrysler welds the stainless exhaust systems with regular
welding material? Can stainless be welded with stainless?

Al
nospam.clare.nce@sny.der.on.ca - 08 Dec 2005 19:56 GMT
>> > So they don't make truly stainless steel exhaust systems that don't rust
>> > at all?
[quoted text clipped - 14 lines]
>
>Al

Chrysler, and virtually all other manufacturers weld with "mild steel"
wire because it is cheaper, easier, and it is "good enough".
And yes, stainless can be welded with stainless wire. It is a little
less forgiving, and works best with TIG, rather than MIG - which makes
it more labour intensive. Robots can MIG quite well.
Gandamack@Afghanistan.net - 15 Dec 2005 01:44 GMT
>>> > So they don't make truly stainless steel exhaust systems that don't rust
>>> > at all?
[quoted text clipped - 20 lines]
>less forgiving, and works best with TIG, rather than MIG - which makes
>it more labour intensive. Robots can MIG quite well.

  For what its worth- I bought a Dodge Caravan new in '89;
put 560,000 klicks on it in commercial use, retired it from my
business in '98- stainless exhaust system lasted the life of the
vehicle, never a problem with it- other maintenance issues with
this stalwart little van were- clutch replaced twice, tranny rebuilt
once, fuel pump replaced twice, timing belt replaced twice, water
pump replaced once.  Otherwise, changed the oil and filter 2x/month;
plugs, wires, rotor and cap every second year.  Original starter,
never replaced, head never removed, at 560,000 k it was using
about a litre of oil per 1000 k.

  If Chrysler still built this beautiful little 2.5 engine I'd buy
another vehicle equipped with it in a second.

  Just my 2 cents worth

      Paul
Tom Lawrence - 08 Dec 2005 23:46 GMT
> Any idea why Chrysler welds the stainless exhaust systems with regular
> welding material?

$$$

My stock exhaust on my '03 wasn't welded anywhere....  it was all crimped to
hell with those damn saddle clamps.

> Can stainless be welded with stainless?

Sure....  ER308 wire with Tri-mix gas (Helium/Argon/CO2) does stainless
nicely on my mig welder.  Yeah - tig is nicer, but it takes too damn long.
If I were welding up some SS pipes on a bench, I'd use my tig.  If I were
welding up over my head, out of position, I'd use (and have used) my mig.

However, that aside, I much prefer band clamps to welding when it comes to
exhaust pipes.  I tend to burn myself much less tightening up clamps, and
don't need the cut-off tool to take it apart later on  :)
Steve Lusardi - 10 Dec 2005 11:47 GMT
Tom,
I don't believe they do. They just don't passivate. Afterall, the exhaust
doesn't have to participate in a beauty pagent!
Steve

>> Any idea why Chrysler welds the stainless exhaust systems with regular
>> welding material?
[quoted text clipped - 14 lines]
> exhaust pipes.  I tend to burn myself much less tightening up clamps, and
> don't need the cut-off tool to take it apart later on  :)
J - 08 Dec 2005 23:19 GMT
It did pretty much look like only surface rust.
>> So they don't make truly stainless steel exhaust systems that don't rust
>> at all?
[quoted text clipped - 7 lines]
> 4-year-old exhaust is starting to show signs of surface rust (and I'm sure
> that's all it is), I'd say it's perfectly normal.
Steve Lusardi - 08 Dec 2005 22:26 GMT
J,
The AISI 300 series Stainless steel are austenetic (non magnetic) generally
pretty and can handle high heat. Kitchen SS is 304, marine SS is 316,
Chemical and food industry is 316TI and 316L. Blast furness, heat treat
manifolds and engine valves are 301 SS. These SS alloys do not corrode
easily, but they work harden, fatigue and crack easily and they have poor
machining characteristics, with the exception of 303. AISI 400 series
Stainless Steels are magnetic and corrosion resistant, not corrosion proof.
They are generally stronger and some alloys can be hardened like 440
(Knives). This series is less expensive, melt at a lower temperature and
resist fatigue better than austenetic types cosecquently they can be
machined, drawn and forged easier. This is the series used for exhaust
systems. All stainless welds will rust even with the correct filler rod.
This is caused by Iron molecule migration to the surface under high heat.
Once welded, the welds must be "Passivated" to prevent excessive rusting.
This can be done both through electro etching or acid exposure, which
removes the surface Iron. Stainless welding can be done using all methods
except OxAct gas.
Steve

> So they don't make truly stainless steel exhaust systems that don't rust
> at all?
[quoted text clipped - 5 lines]
>> Rust is the result of oxidation of iron.  Stainless steel, although
>> containing a fair amount of chromium and nickel, is still mostly iron.
nospam.clare.nce@sny.der.on.ca - 09 Dec 2005 02:04 GMT
>J,
>The AISI 300 series Stainless steel are austenetic (non magnetic) generally
[quoted text clipped - 15 lines]
>except OxAct gas.
>Steve

Now you tell me, AFTER I welded my stainless steel mower deck to the
mild steel frame.With my acet. torch and mild steel wire.

 

>> So they don't make truly stainless steel exhaust systems that don't rust
>> at all?
[quoted text clipped - 5 lines]
>>> Rust is the result of oxidation of iron.  Stainless steel, although
>>> containing a fair amount of chromium and nickel, is still mostly iron.
 
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