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  #1  
Old 07-26-2017, 06:55 PM
computersoc computersoc is offline
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Default Damaged ebrake cable / muffler

My exhaust pipe between the muffler and cat broke last month:
Cracked exhaust pipe

I did a temporary repair with muffler tape, pipe glue and a clamp. I had an appointment scheduled this Saturday at a shop to get it fixed. My fix the other day broke. I put it back together with the clamp and I went to drive the truck today and heard a loud bang and found the muffler all jammed up. Lucky I was only a half mile from home so I just pulled up the part hitting the ground a little and made it home.

Any guesses on what I damaged? Is that the ebrake cable that goes across the rear differential? I see it looks torn up. The ebrake pedal went to the floor when I was on a hill but held with the truck in 1st gear. When I leveled the truck out, the e brake pedal was hard as a rock. Can just that cable be replaced or the whole ebrake system needs to be replaced? Part number(s)? I need only Ford ebrake components on this truck. It hates aftermarket ebrake cables for some reason.

I don't know what the muffler hit when it broke from the mount, but it was LOUD. Any chance the rear differential or shock got damaged?

What is salvageable from the picture of the muffler to the tail pipe? What will that cost in parts? The shop I go to only charges $50 an hour labor (which is why they are booked out so far).

The metal service brake lines don't appear to be damaged and the truck braked fine. I'm guessing I can just pull or cut the muffler out and then drive it to the shop?

I did hear psh psh psh a couple times as I was driving the second before it broke. Not sure what that was from but I don't see any leaks in my driveway.

Can this all be fixed in a few hours? I had other plans this Saturday right after, thinking it was just having them fix where the muffler pipe cracked, but now this.
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Last edited by computersoc; 07-26-2017 at 06:58 PM.
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  #2  
Old 07-26-2017, 07:28 PM
cowboybilly9mile cowboybilly9mile is offline
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Default Re: Damaged ebrake cable / muffler

From a quick glance at the pics it looks like:

* Exhaust - parts and labor from that cracked and now failed joint all the way back. Just let the muffler shop make the call and do it right, and pay the $ for the 409SS pipe and not the crappy aluminized steel.

*Shock looks bent, go out and inspect. Replace if bent.

*Sounds like and maybe from the pic, there is a damaged parking brake cable(s?). This is something you can replace yourself, NAPA carries them and they are Raybestos.

*Cost for parts can be found by visiting NAPA and other sites for shocks.

*Do a good visual under there for damage.

***You need to decide what is more important to do this Saturday, fix the vehicle or do something else. As you've seen, neglecting needed repairs has caused further damage and it'll now cost more to make things right, so this might be a motivator and help with the decision. It could have been worse, mufflers have been shed from vehicles, flew into the windshield of the car behind and caused a bad wreck.
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  #3  
Old 07-26-2017, 07:37 PM
computersoc computersoc is offline
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Default Re: Damaged ebrake cable / muffler

The plastic cover on the shock is moved. Is there an easy way to tell if it's bent once the muffler is taken off that plastic piece?

Prior to this, the muffler itself was just rusted but maybe 4 years old. Is it a good idea to just get it replaced with a new one?

Are the exhaust pipes and tail pipes expensive? I basically will probably need from the break in the pipe to the muffler, then a new tail pipe from the other end of the muffler. But I'll still let the shop decide what they want to do with it. I'm just trying to get mentally prepared for the price tag (ie. is this even worth it on a truck with 215k miles?).

Thanks.
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  #4  
Old 07-26-2017, 08:05 PM
jim22 jim22 is offline
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Default Re: Damaged ebrake cable / muffler

I just put on a walker cat back system. It was about $250 for parts at the local carquest. One local shop wanted $850 to do the same thing with the same parts. You might have some work to do on the cat pipe too.

Iim
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  #5  
Old 08-01-2017, 08:25 PM
computersoc computersoc is offline
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Default Re: Damaged ebrake cable / muffler

The shock is indeed stuck. Can it be driven like that to the repair shop that is about 30 minutes away? When I drove a half mile back to my house after the muffler broke, I didn't notice anything too bad but I didn't hit any potholes or sewer covers. The driver side of the truck bounces like it should if I move the bumper up and down but that passenger side shock just stays stiff and doesn't move.

The shock was replaced 60k miles ago (Bilstein). Can I get away with buying just one or should I have both replaced?
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  #6  
Old 08-02-2017, 03:50 AM
modelageek modelageek is offline
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Default Re: Damaged ebrake cable / muffler

Quote:
Originally Posted by computersoc View Post
The shock is indeed stuck. Can it be driven like that to the repair shop that is about 30 minutes away? When I drove a half mile back to my house after the muffler broke, I didn't notice anything too bad but I didn't hit any potholes or sewer covers. The driver side of the truck bounces like it should if I move the bumper up and down but that passenger side shock just stays stiff and doesn't move.

The shock was replaced 60k miles ago (Bilstein). Can I get away with buying just one or should I have both replaced?
It would be best to free up or remove the shock but if you can't then just drive slow and careful? Can you do the repairs yourself? CAT back Exhaust system on these are a POC once you get the old old system off. Getting the old system off is a poc if you use a grinder or dremmel tool, etc. The exhaust system, 2 shocks and 2 rear cables would cost $250 total from Rockauto. I'm a backyard tech and would do all those repairs in under 3 hours.


FYI: having done all 3 of those repairs on Rangers multiple times. The ebrake cables are the most challenging(but still very doable for average person. The exhaust is very very easy to do. Takes me about 30-45 minutes. It's a total of 6 nuts and bolts.
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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).

Last edited by modelageek; 08-02-2017 at 06:58 AM.
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  #7  
Old 08-02-2017, 07:22 AM
computersoc computersoc is offline
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Default Re: Damaged ebrake cable / muffler

In terms of the shock, would I just need a ratchet set to replace it?

Do I need to take the drums off to replace the ebrake cable? They're quite a pain to get off.
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  #8  
Old 08-02-2017, 07:37 AM
RoberticusMaximus RoberticusMaximus is offline
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Default Re: Damaged ebrake cable / muffler

yes, rear shock is a 5 minute deal with a ratchet/socket on one side, end wrench on the other, and likely some penetrating oil. just a top and bottom bolt.
...second though, maybe a hammer and a punch might be helpful with the bolts if there was damage to the bushings. either way, no big deal i'm sure.

a hint on the drums - if they are stuck on and you can't get them off, swing by a auto shop and have them inspect the rear brakes. they''ll pop them off for you. they'll be way easier to get off after that lol!
...and i assume you would need to pull the drums to do the cables, though i have not done them myself. but the cables go in through the back/inside and connect to a lever on the shoes.

Last edited by RoberticusMaximus; 08-02-2017 at 07:40 AM.
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  #9  
Old 08-02-2017, 08:08 AM
cowboybilly9mile cowboybilly9mile is offline
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Default Re: Damaged ebrake cable / muffler

Quote:
Originally Posted by computersoc View Post
In terms of the shock, would I just need a ratchet set to replace it?

Do I need to take the drums off to replace the ebrake cable? They're quite a pain to get off.
Back off the self adjusters before attempting to remove the drums. On the shock, out of concern of further bending (or breaking) it and causing other, new problems, I too would remove it. As for replacing it (them), 60K is a long time, as such, replace as a pair. Things might be different if it was 5 or 10K. On the cables, if you are doing the replacement yourself and are hesitant about getting things back together correctly, take pics before disassembly. NAPA sells those cables, they are Raybestos parts in a rebadged box for NAPA, and they are very cheap. You may save a few bucks with Rock on this one, but if this is all you are ordering from them then is probably not worth the wait and possibly, shipping cost.
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  #10  
Old 08-02-2017, 08:18 AM
modelageek modelageek is offline
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Default Re: Damaged ebrake cable / muffler

Quote:
Originally Posted by computersoc View Post
In terms of the shock, would I just need a ratchet set to replace it?

Do I need to take the drums off to replace the ebrake cable? They're quite a pain to get off.
Yup, you only need a ratchet to do the shocks. 6 point sockets are best. 1/2" ratchet or breakerbar are helpful. Start hitting the bolts with penetrate now.

You need to remove the drums to change the ebrake cables. You said the ebrake is working a little? Are the ebrake cables cut or snapped at all? You might wait on the cables and do the exhaust and shocks first. See how that goes. They are easier then the cables. If you do the cables I would be glad to explain the details of how to do them.

Gather together a grinder and sockets and order the stuff from Rockauto. You can remove the exhaust system and shocks while you wait for the parts. That's the harder part, install is easy.

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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).
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  #11  
Old 08-02-2017, 08:29 AM
computersoc computersoc is offline
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Default Re: Damaged ebrake cable / muffler

The e brake cable that goes across the rear differential is cut in two places but not all the way through.

I've ordered from Roc auto before. Will I need specific part numbers to order the cat back or do they have pre made ones? One website asked for my wheelbase, which I was unsure of.
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  #12  
Old 08-02-2017, 08:37 AM
modelageek modelageek is offline
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Default Re: Damaged ebrake cable / muffler

Quote:
Originally Posted by computersoc View Post
The e brake cable that goes across the rear differential is cut in two places but not all the way through.

I've ordered from Roc auto before. Will I need specific part numbers to order the cat back or do they have pre made ones? One website asked for my wheelbase, which I was unsure of.
You buy the appropriate kit for your wheelbase. What is your wheelbase? I'm guessing it is 112". Also search for a 5% off discount code.

For the cables You need to know if you have 9" or 10" rear drums. I'm guessing 9". You can tell my looking at the drums. 9" have fins, 10" are smooth
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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).

Last edited by modelageek; 08-02-2017 at 09:04 AM.
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  #13  
Old 08-02-2017, 11:30 AM
computersoc computersoc is offline
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Default Re: Damaged ebrake cable / muffler

How does this kit look for $229? I know 409SS was previously mentioned and this doesn't appear to be it.

Also the tail pipe near the spout was held up with a piece of rubber, I'm guessing to dampen bumps. Where do I get that piece since I had to cut it off to get the tailpipe off.

Thanks!
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Last edited by computersoc; 08-02-2017 at 11:35 AM.
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  #14  
Old 08-02-2017, 11:35 AM
RoberticusMaximus RoberticusMaximus is offline
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Default Re: Damaged ebrake cable / muffler

yeah, that rubber part, if its not listed under bushings for the exhaust, it might be listed as an 'isolator' since it isolates the engine rumble through the exhaust form coming back in the cab through the frame rail lol, it sounds kinda grumbly without those. well with some trucks at least.

you might also look for the key work 'hanger bushings' ... not sure... i'd like to know exactly what that part is called too
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Old 08-02-2017, 11:36 AM
modelageek modelageek is offline
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Default Re: Damaged ebrake cable / muffler

It's called a Hanger or Insulator.

Most of the time you don't need to cut it to remove the old system. I just grind off what I need to get the system off.
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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).
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