540 exhaust flange

[yaofeng]

The complete exhaust on my 95 540 was removed for the 6 speed conversion. Those of you who have messed with the exhaust know what a PITA it is. Between the end of the cat and the rear section the pipes are connected by four loose flanges. Three of the four loose flanges are locked behind flared pipe end. The last one has a straight end and is kept from falling off by a seal ring. All four flanges have rusted stuck bolts on it after 10 years of use.

http://i21.photobucket.com/albums/b274/yaofengchen/DSC_3109.jpg

When I did my 525 last year I drilled the stuck bolts out with the flanges in place. I got smarter this time. I bought a pipe flaring tool. Stuck it in the pipe. Use a 16 oz. hammer to unflare each pipe end. Remove the old flange. And push the new flange in. I will use the tool to flare the pipe again. These flanges are $16 a piece from the dealer. But it beats drilling.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3191.jpg

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3192.jpg

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3193.jpg

I bought three flanges from the dealer, part #18111719371, item 4 in the link,

http://www.realoem.com/bmw/showparts.do?model=HE63&mospid=47410&btnr=18_0210&hg=18&fg=20

They have 55 mm ID and fit snugly onto the pipe I un-flared. But the last one has 59 mm ID and I cannot find it on the etk. According to the etk, all flanges are identical. But they are not. Help!!!

[632 Regal]

thats messed up. I can see ones bigger, check a different year?

[yaofeng]

I am talking to the dealer hoping they can help me. I wouldn't know where to start. The etk doesn't give you any dimensions for the loose flange. If I can't get one new, I'd have to drill the bolts out from the one removed to reuse it.

[Jr ///M5]

I used steel flanges from the muffler shop. Split them open with a bandsaw and welded them back together once they were back on the muffler.

It was cheap, quick and painless.

Jr