I have a 2002 3.0 4x4 and the exhaust flange between the catalytic converter and the muffler broke causing the two pipes to separate. The same thing happened on my old '95 with a 2.3. The problem is that aftermarket and replacement flanges that I've looked at won't work- and I'm not going to spend $400+ on a whole new exhaust when the only problem is the flange.

Anybody had the same problem or can offer some advice?

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Bantl1jj

'02 3.0 4x4 ext. cab 5 speed. (MAZDA)

If you have access to a mig then I would just weld them together.

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1997 Ford Ranger 2.3 5 speed manual, 3:73 7.5 Rear, BFG T/A 235/70/R15, 2 1/2" flow master 40.
2006 Ford 500. Mercedes-Benz luxury at a 1/3 of the price.
97 XLT 2wd, 3.0, Auto/Man swap 4" RC suspension lift, 8.8 swap w/4.10's and T Loc, 15x8 Soft 8's, 32" Kenda Klever MT's

Yeah the only problem with that is the flanges had spring bolts to allow a little flex. I was told that if it's welded solid at that connection, it could cause another connection to break.

I'm thinking about cutting that section out and welding in a piece of that flex/spring pipe unless anybody has a better idea.

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Bantl1jj

'02 3.0 4x4 ext. cab 5 speed. (MAZDA)

Mines held together for over 2 years now.

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1997 Ford Ranger 2.3 5 speed manual, 3:73 7.5 Rear, BFG T/A 235/70/R15, 2 1/2" flow master 40.
2006 Ford 500. Mercedes-Benz luxury at a 1/3 of the price.
97 XLT 2wd, 3.0, Auto/Man swap 4" RC suspension lift, 8.8 swap w/4.10's and T Loc, 15x8 Soft 8's, 32" Kenda Klever MT's

I removed my flange, it was rusted to hell and the spring bolts were terrible to get off. So I run two cats no muffler now.
But I would go junkyard hunting man

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1993 Ford Ranger Splash 4.0
Regeared to 3.73's, Ultra 15x7 rims, 235/70/15 Yokohama Geolandar AT/S tires.
Mods: plastidipped grill and header panel, Throttle cable mod, aftermarket projector headlight and corners, Alpine CDA-105 Headunit, 2 MTX TS82 8" subs in trick boxes, strobe lights on front of truck. K&N drop in filter, 2.5" exhaust after catalytic converter to a Thrush Welded muffler, pipe exits at stock location.