Seems like I'm post a lot - maybe my Pacifica has reached that age.

Two major sections of my exhaust are splitting apart - the front pipe from the Y-pipe to the front muffler, and then the whole long pipe, resonator, rear muffler welded assembly. Amazing, the front muffler in between these two sections is OK. My service guy says the long rear assembly (long pipe, resonator, rear muffler, tailpipe), part#68038111AA was a one-year part. and Chrysler stopped making replacement parts for them in 2015, and since it was a one year part, no aftermarket company makes it.

Now, 2007 was the dual exhaust year, but prior to that, the rear section assembly looks identical to the 2008 Pacifica in the junkyard Pacifica's (my pic-a-part has 9 Pacificas from 2004's to 2008's). Unfortunately, I can't find any Chrysler specific places that have the rear section, and only a few that have the front pipe. I did notice that for some of the older Pacifica's, Walker makes a kit that includes the front muffler, long pipe, resonator, rear muffler, and tailpipe. Has anyone tried to tie together the front pipe with this Walker setup from the front-pipe back?

My repair guy says he's out of options to make my Pacifica pass PA state inspection. I'm tempted to buy the front pipe from Chrysler, and mix/match/bend the Walker rear section to fit my 08 AWD Pacifica. If anybody has any thoughts, let me know.

I hate to give up on a vehicle (although it has some other questioning issues) when its not rusted out, the AWD and the A/C still work, and it handles my 70 mile commute each day.

Thanks,

Dave

 

For anyone that finds themselves searching here, the Walker muffler kit that fits the 2005 3.5 V6 Pacifica pretty much fits the 2008 4.0 V6 AWD, and I assume the FWD. I bought the kit at Rock Auto with the part numbers below. The rubber hanger mounts all matched up, but the tailpipe is a shade off center to the passenger side. I might put a shorter rubber hanger on that side to pull it dead center in the rear bumper cover opening for the tailpipe.

Part NumberPart TypePrice EACore EAQuantityTotal

2005 CHRYSLER PACIFICA 3.5L V6

WALKERKIT5580482Exhaust System Kit$ 230.79-1$ 230.79

WALKER35337[Kit Component] Clamp$ 1.26$ 0.003-

WALKER21498[Kit Component] Muffler / Resonator$ 64.67$ 0.001-

WALKER47798[Kit Component] Muffler / Resonator$ 50.14$ 0.001-

WALKER21485[Kit Component] Muffler / Resonator$ 109.30$ 0.001-

WALKER31647[Kit Component] Pipe Flange Gasket / Seal$ 2.90$ 0.001

 

Also, if you need to change the front pipe (still available at some online Chrysler parts dealers), the mounting studs can be accessed by pulling the passenger side front tire and pulling the plastic fender liners out. My Pacifica is 11 years old, the studs were giant lumps of rock hard rust. I ended up using a sawz-all on the front-pipe side nuts of the flange, and also on the manifold side of the flange. That left me about a 1/2" of stud sticking out of the manifold flange that I thought would just fall out. Not a chance. I did a dozen cycles of heating to cherry red with a MAPP gas torch, and probably a whole can of PB Blaster, and they never budged. I decided I would cut the studs out flush with the sawz-all, and then drill the flange holes. Thankfully and surprisingly, the reversing action of the sawz-all cuts on the studs actually pulled them out of the manifold flange. Its tough access through the passenger front wheel well, but it was doable.